I had this problem on my 96 Explorer. On the Explorer, hot water is always running through the heater core. There is a door inside the duct that blends the hot air that passes over the heater core and the cold air that passes through the A/C coil. The door is acuated with a small electric motor that is mounted to the top of the duct under the dash. On mine, the motor turned the door too far, and the door eventually cracked. It would have cost $800 for the dealer to replace the whole duct unit. Instead, I cut a slot in the bottom of the duct and pulled out the door, glued together the broken parts, reinstalled the door, and reinstalled the bottom section of duct. Then, I put JB weld on the heater knob so it wouldn't turn as far to prevent it from happening again. When I cut the slot in the bottom of the duct, I only cut three sides, so that one side was still attached to the duct, and I just bent down the part I cut to get the door out.
Friday, May 23rd, 2008 AT 12:16 PM