97 Explorer AC/Heater problem

Tiny
BYHISDESIGN
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  • 1997 ALL OTHER MAKES ALL OTHER MODELS
I have a 97 explorer, 5.0 AWD with 143,000 miles. Purchased as second owner and was told from the original owners they always had problems with controls working correctly. Motor speed only worked on low and high which I corrected with new resistor pack. During winter, the heater always blew hot however the temp control would never regulated to a cooler temp. Not an issue as we just shut off heater control. We noticed when the heater was shut off, cold air can be felt on passenger side floor.
The AC did blow cold (switch in AC MAX mode) but towards the end of season temp felt warmer than normal. Thought this was just needing recharged at the time. This last week I had the AC service however the cold air in the vents was only cool at best. Pressure is good and compressor works as it should as told by service people. If you feel above the plenum, it is colder than the air coming out the vents.
I now only have low and high motor speeds again but I can not get cold air out of vents.
Here's is what I have found, looking through the glove box, the vent on the right side of plenum box opens and closes with selector control from heater to AC. The motor on top of plenum DOES work with changing of temperature selction from cool to hot as I popped the motor off the posts and verified it was operating. Is there a vaccum control which is not allowing the system to operate or is it the control unit in the dash? I have not replaced the resistor pack again for the motor and was wondering if that may be causing the problem. Any suggestions would be most appreciated.
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Sunday, May 13th, 2007 AT 11:05 PM

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Tiny
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No it does not have Auto Temp, just a standard blue to red temp knob in the center. To the left is fan speed then the right of that is the control to regulate air flow. MAX AC, AC, Figure with arrow to head (I think that should be straight outside air to dash vents) then OFF position. Three more figures with arrows and defrost vent sign. When I turn this control knob I hear air channeling through the different ducts and the right side heat plenum flapper works under the dash.
I do not get any change in sounds with movement of the temp knob and no real change in temp output either from cold to hot or hot to cold that is with the engine motor at normal operating temp.
Hope this answered the question. Didn't mean to write an essay.
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Monday, May 14th, 2007 AT 12:37 PM
Tiny
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Fuse is good.I don't think I really like the idea where this has gone. It doesn't sound like an easy fix. Do you think there is any possible way to cut the plenum with a dremel then reseal the case with a fabricated 'door'? (I am handy with tools) Just a thought. Why in the world don't they make things out of metal any more.I know. $ 0.15 v.S. $ 0.02 per car. Plus the cost benefits to the service department.

Thanks for your help I do appreciate it.
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Wednesday, May 16th, 2007 AT 11:01 AM

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