On my 2004 mountaineer the temp control stopped working yesterday. No matter where you set the hot/cold blend **** it blows hot air. I tried selecting A/C and MAX A/C but still only get hot air. I can switch to floor/dash/defrost vents OK but it is always hot air regardless of the vent selected.
With the ignition switch ON I can hear what sounds like an actuator motor when I rotate the temp control **** coming from the drivers side under the dash.

 

i copied this sometime back--- your problem is the mixing door that takes hot and cold air and blends to get the righ temp.

2002 explorer blend door--- feb 5, 2007 post

#1 pulled trim piece around radio and heater/Ac control ( unplugged heater/ac control)
#2 pulled center console out ( dont forget to remove to screws from back corner of console, you will have to pop off the corner plastic pieces to see these screws)
#3 removed the bottom part of dash under steering wheel ( 2 screws)
#4 removed metal dash support ( piece that goes from floor to dash behind the consloe, two nuts from floor and two bolts from dash)
#5 pulled the floor vent duck work from driving side ( 2 screws )
#6 removed several screws form dash in middle so it would move a little ( you may not have to do this but I did just trying to make it easier to get to the actuator)
#7 pulled the actuator ( 3 screws) and unplugged)
the top screw on top back corner is rough to get to .

you will need a 1/4 inch ratchet with a 7 and 8 MM socket, I also used a three inch extension on some of the screws.
you will also have to have a 8mm wrench to remove the actuator.


I replaced my actuator, it was not turning at all,appeared that the gear inside was gone.
You do not have to get this from the dealer. Advanced Auto ordered one for me. I had it the next day.I paid 49.88. I also found that a Hanyes manual was helpful also ( 18.00)Make sure you get the manual for the correct year you have. I was told that the 2002 and 2003 where the same. The manual I bought was for both years.The wording was not helpful ( as far as locating the front actuator but looking at the pictures helped alot.

I worked on and off on this a couple of days ( took some things apart that was not needed, I was trying to use the steps someone had told me about for a late 90's model, they are notset up the same way.
Once I figured out what had to be done I figure I had a couple of hours in on this.
You could make it easier to get to the actuator if you pullled the complete heater box off but this requires more things to take off ( to do this you would have to unhook and pull the heater core out0

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Thanks for that info. I read somewhere that the symptoms for a broken door were different than mine. It said if it was the door then I would still have max AC because it uses different ducting or something. I don't have max AC.

 

the electric variable blend door controls the temp, no matter what. the direction of the air flow from defrost, panel, floor, etc is controlled by a series of vacuum operated doors. all MAX does is use inside air to the AC instead of the warmer outside air. makes the output cooler since the input is cooler.

 

OK, thanks Steve. I'll get started this afternoon, I have been reading that there is a good chance the door itself is broken. If it's not the actuator I found a blend door repair kit on ebay for $120 or just the door itself for about $15. The kit involves cutting out a hole to get to the door instead of removing half the car to get to it. We'll see, maybe it is just the actuator.


Thanks again!

 

Is the mountaineer location the same as the explorer (behind the glove box)?

 

Got into it tonite and pulled the actuator out, once you get it out of the vehicle it comes apart very easily, just has clips holding the case together. I opened it up and the small gear had a broken tooth, I just pulled it up and rotated it 180* and put it back together. tried it out and the AC works again so I put everything back together. Probably should have changed out the actuator while I had it out but it was late and I was feeling lucky :-)

Oh, and I discovered that 2 screws will hold the actuator just fine, that third one on top is a BITCH!!!

The Mountaineer IS NOT the same as everything I read on the Explorer, the actuator is not behind the glove box, it's behind the temp controls!!

Thanks for the help steve.

 

you were reading the instructions for the mid to lat 90s EXP, after 2002, you need to follow the directions i gave above for the under the radio location. the glove box removal method works for the 96-98 models.