2002 Ford Explorer blend door

Tiny
SHIMMER
  • MEMBER
  • 2002 FORD EXPLORER
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 88,000 MILES
The blend door is stuck in one position. Will not open for heat. The vaccum is good. When in heat position there is a clicking sound. When turned turn to the cold the sound stops. Something is restricting it from opening. What needs to come apart to get to it
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Sunday, December 7th, 2008 AT 10:34 AM

1 Reply

Tiny
DAVE H
  • EXPERT
This is a BIG job? The book times are 7 hours L/H and 3 hours R/H. I have took the diagrams off the explanation. Let me know if you need any? Good luck

REMOVAL AND INSTALLATION
Instrument Panel
Removal and Installation
Remove the driver air bag module. For additional information, refer to AIR BAG RESTRAINT SYSTEMS.
Remove the passenger air bag module. For additional information, refer to AIR BAG RESTRAINT SYSTEMS.
Remove the screws and the instrument panel steering column cover.

Loosen the bolt and disconnect the instrument panel to body harness bulkhead electrical connector.
Loosen the bolt and disconnect the bulkhead electrical connectors.
Disconnect the pedal control harness electrical connector.
Remove the screws and position the parking brake release handle bracket aside.

Remove the screws and the lower steering column cover.
If equipped, disconnect the shift cable from the steering column.
If equipped, release the shift cable from the steering column bracket.
Remove the pinch bolt and disconnect the intermediate shaft from the steering column shaft.
Remove the floor console. For additional information, refer to FLOOR CONSOLE.
Position the wiring harness aside.
Remove the ground wire bolts.
Disconnect the electrical connectors.

Remove the two instrument panel center support brackets.
Remove the four bolts.
Remove the four nuts.
NOTE:This step is carried out through the glove compartment opening.

Disconnect the vacuum harness connector and the two electrical connectors.
Disconnect the radio antenna in-line connector.
Raise the glove compartment door.
Remove the passenger front door scuff plate.
Remove the pin-type retainer and the passenger A-pillar lower trim panel.

Loosen the bolt and disconnect the bulkhead electrical connector.
Remove the ground wire bolts and disconnect the electrical connectors.

Remove the passenger assist handle covers.

Remove the bolts and the passenger assist handle.

Remove the two windshield side garnish moldings.
Remove the instrument panel defroster opening grille.
If equipped, disconnect the electrical connector.
Remove the instrument panel cowl top bolts.
Remove the cowl grille..
From inside the engine compartment, remove the instrument panel support bolt.
Remove the two instrument panel side finish panels.
Remove four instrument panel cowl side bolts.

NOTE:This step may require an assistant.

Remove the instrument panel.
To install, reverse the removal procedure.
Floor Console
Removal & Installation
All vehicles
Release the two floor console front clips (one each side).
Vehicles with manual transmission
Remove the gearshift lever handle.
All vehicles
Remove the console finish panel mat.
Vehicles with automatic transmission
If equipped, remove the ashtray assembly.
Disconnect the electrical connector.
Remove the console finish panel screw.
All vehicles
Remove the console finish panel by lifting up at the rear and sliding it rearward.
Disconnect the electrical connector(s).
Remove the floor console front screws.
If equipped, disconnect the electrical connector and release the wiring harness locators.
Remove the floor console center bolts.
Remove the two floor console access covers (one each side).
Remove the two floor console rear bolts (one each side).
Remove the floor console by lifting up at the rear of the console and sliding it rearward.
To install, reverse the removal procedure.

Instrument Cluster Finish Panel
Removal & Installation
Remove the instrument panel center finish panel.
Disconnect the electrical connectors.
Remove the screws and the instrument panel steering column cover.
Remove the lower steering column shroud.
Remove the screws.
Remove the shroud.
Remove the upper steering column shroud.
Release the retaining clips and rotate the upper steering column trim panel out of the instrument cluster finish panel.
Remove the upper steering column shroud hard shell.
Remove the five screws and the instrument cluster finish panel.
Disconnect the electrical connectors.
To install, reverse the removal procedure.

Temperature Blend Door Actuator - LH
Removal and Installation
Remove the floor console. For additional information, refer to INSTRUMENT PANEL AND CONSOLE.
Remove the lower steering column opening finish panel.
Remove the screws.
Disengage the retaining clips and remove the lower steering column opening finish panel.

Remove the LH center instrument panel support brace.
Remove the bolts.
Remove the nuts and remove the brace.
Remove the screws and remove the LH floor duct.
Remove the screws.
Remove the screw and detach the LH temperature blend door actuator from the heater core and evaporator core housing assembly.

Disconnect the electrical connector and remove the temperature blend door actuator.
To install, reverse the removal procedure.

Temperature Blend Door Actuator - RH, DATC
Removal and Installation
Deactivate the supplemental restraints system (SRS). For additional information, refer to AIR BAG RESTRAINT SYSTEMS.
Remove the floor console unit. For additional information, refer to INSTRUMENT PANEL AND CONSOLE.
NOTE:RH shown LH similar.

Remove the instrument panel center support brackets.
Remove the four bolts.
Remove the four nuts.
Remove the assist handle bolt covers.
Remove the bolts and the passenger assist handle.
Remove the windshield side garnish moldings.
Remove the defroster opening grille.
Remove the upper instrument panel support bolts.

Remove the exterior cowl grille.
Remove the instrument panel support bolt.
NOTE:RH shown LH similar.

Remove the two instrument panel side finish panels.
Lower the glove compartment.
Loosen half way the LH instrument panel side support bolts.
CAUTION:Be sure the instrument panel is properly supported to avoid possible damage to the instrument panel wiring and components.

CAUTION:To avoid damage to the instrument panel wiring or components, do not use excessive force when moving the instrument panel away from the dash panel.

NOTE:The instrument panel may be supported by installing threaded rods or equivalent, with the same diameter and thread pitch, in place of the instrument panel support bolts.

Correctly support the instrument panel and remove the RH instrument panel support bolts to allow the instrument panel to be pulled away from the dash panel.
Position aside the floor airflow vacuum control motor.
Remove the screws.
Disconnect the vacuum connector.
Position aside the floor airflow vacuum control motor.

Remove the RH temperature blend door actuator.
Remove the screws.
Disconnect the electrical connector.
Remove the RH temperature blend door actuator.

To install, reverse the removal procedure.
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Sunday, December 7th, 2008 AT 8:13 PM

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