2002 Mercury Sable 6 cyl Two Wheel Drive Automatic 165000 miles
1. I researched and there is a TSB on this from Ford for the Blend Door Binding or Sticking.
2. I purchased a blend door from Ford for $6.00.
3. I looked at the blend door and all Ford did was cut a piece of the rubber seal off to prevent it from binding or sticking, so instead of breaking the air unit apart to replace the door, I cut the seal with a razor blade.
4. Still no heat after reassembly.
5. The next day I flushed the cooling system. I know, should have done this first. I measured the output of the heater at 150 degrees after the flush.
6. Replaced with fresh coolant. Heater worked fine.
7. Got in the car this morning and no heat.
I worked on the car in a shop that was heated. Is it possible that once the blend door warmed up, it worked fine, but when I let it sit overnight in 20 degree temperatures, the door is less pliable and then binds? It's either that or the blend door actuator is not working. Just want a second opinion.
Monday, January 11th, 2010 AT 9:41 AM