2001 Ford Windstar

I had the same problem and gear inside the blend door motor was broke. The blend door motor is behind the radio area. It is the small, 2-3 inch, white box. Another possibility is the black piece the blend door goes into is broken. Expensive to fix but usually can be 'fixed' with a nail. I would guess the blend door motor, sounds just like what mine did.

I can't really see how to get back there, but I assume that huge trim piece comes off, you know, the one that has the ash tray, cup holders, etc. If I can find it and 'fix' it with a nail I will very pleased. The vehicle is not worth what it would cost at the dealership. I appreciate your help.

I took the radio out then the bottom center piece by the cd storage area and could get to it. I think it was a little tight but doable. I could reach up from below with a pair of plyers and turn the white gear and change it to heat. Thats how I figured out that it was the blend door motor, might officially be called blend door actuator. I told the part guy what it looked like and he new exactly what it was