Ford F-250: How to Replace Your Blend Door Actuator

Here's how to replace your blend door's actuator and ensure you get hot and cold air when you want in your Ford F-250 or F-350 Super Duty.

By Thom Cannell - November 17, 2014

This article applies to the Ford F-250, F-350 Super Duty (2005-2014).

The blend door actuator is responsible for controlling the hot and cold air mixtures in your Ford F-250 or F-350 Super Duty. Here's how to replace the blend door actuator yourself and save some labor money.

Materials Needed

  • Screwdriver
  • 7mm, 10mm sockets
  • Plastic panel removal tools
  • 1/4” or 3/8” ratchets
  • Needle nose pliers

Pro Tip

Do you have a single or dual zone control system? If the passenger can’t set their own heat, it is a single zone system. Those systems will have a single top-mounted actuator behind the radio. Automatic Temperature Control-equipped dual zone trucks have two; the second actuator is low, located above the transverse air duct.

Step 1 - Ensure temperature control works

Does the temperature controller work? The related article below provides instructions for testing the manual controller, a simple potentiometer. Your problem might be as simple as a broken or shorted wire.

  • Figure 1. Wiring diagram.
  • Figure 2. Plug diagram.

(Related Article: Air Temperature Variable Resistor Test -

Step 2 - Remove the fascia

Once certain the temperature control works, you’ll need to get behind the surface, removing the fascia. You’ll need to remove the trim panels, radio, and climate control panels.

  • Figure 3. Unscrew the fascia.
  • Figure 4. Remove the fascia.

Featured Video: How to Remove the Fascia

Pro Tip

Don't use screw drivers; they leave marks. Invest in a plastic panel pulling kit for under $20.

Step 3 - De-power the airbag

To safely work on the top-mounted actuator you’ll need to de-power and disconnect the airbag. Failure to do so is incredibly dangerous as the airbag could cause serious injury. Disconnect batteries and bleed off residual charge before working with the airbag. Do not reconnect batteries until the airbag is reconnected.

Figure 5. The airbag must be de-powered.

(Related Article: How to Safely Remove an Airbag -

Step 4 - Expose ducts and remove airbag

After the instrument trim panel, audio system, and climate control panels (most use 7mm screws or clips) have been removed, lower the glove box by squeezing each side to center and safely remove the air bag after de-powering (see caution in Step 3 above).

Figure 6. Finish removing the airbag.

Step 5 - Remove air duct

Regardless if you have a single or a dual system, you’ll have to remove the upper air duct behind the glove box, or remove the screw behind the center stack and push the ductwork back, removing an elbow. Watch the video. The upper actuator is located behind and below the removed elbow.

Figure 7. Remove air duct.

(Related Article: Actuator Installation -

Step 6 - Remove screws securing actuator to blend door shaft

Remove the screws and replace the blend door actuator. It self-indexes and should drop in.

Figure 8. Remove the indicated screws securing the actuator.

Step 7 - Secondary actuator removal

The secondary actuator is low, under the center stack. You’ll have to move, remove, or damage the transverse air duct to get the actuator out.

  • Figure 9. Location of secondary actuator
  • Figure 10. Another angle for the secondary actuator.

Step 8 - Replace everything in reverse order

Reverse your procedure and finish up.

  • Install the blend door and tighten the screws.
  • Install the airbag back, the glove box, and the fascia.
  • Re-connect the battery and test your AC.

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