2003 windstar:blower works no heat, plus clicking noise

jrdodgerfan · 02-10-2007, 02:33 PM

I have 2003 windstar. The blower works but there is no heat in front. Also there is a clicking noise, at certain points of these control sliders the noise will go away. Could anyone help me find the problem. Thanks.

garync1 · 02-10-2007, 03:11 PM

Part number should be the same but check with year at dealer. XF2H-19E616-FB
BLEND DOOR MOTOR.. Remove stereo with Din tool Advanced auto has them. Also Push sides of glove box in and glove box will drop. I will try to pull up photo and post site. 4 bolts hold the motor in D slot so no mistakes on install just may need to turn blend door motor to make bolt holes line up. What happens is the plastic gears wear out in side the motor.http://good-times.webshots.com/album...VdTPOV?start=0
The last photos are the blend door and page 2 are the rest..

jrdodgerfan · 02-10-2007, 08:19 PM

Great thanks for your help. Hopefully this works. Do you have any idea how much they cost & are they hard to replace. I know how take the radio out & all. Thanks again.

garync1 · 02-12-2007, 03:38 PM

Quote:

Originally Posted by jrdodgerfan

Great thanks for your help. Hopefully this works. Do you have any idea how much they cost & are they hard to replace. I know how take the radio out & all. Thanks again.

Ford Dealer the only place i know that has it.. it cost me about 56.00. And not that hard of a job..Pull radio, and drop glove box.. thats the only thing you need to do.. I used a 1/4 inch rachet small enough to get in there..

jrdodgerfan · 02-26-2007, 01:08 PM

Hey Gary thanks for the great advise along with the pictures to go with it. Its all good, was an easy job like you said & my wife is happy that she has heat again. Thanks alot.

kc8avv · 03-03-2007, 07:49 AM

Hey guys, I have the same problem with my '99 and after talking to the parts guys at the Ford dealer, He told me it usually is the door that breaks and not the gears in the motor. I am looking for others who have dug into this and can prove/disprove, or find it is 50/50 in occurances.

I am trying to get into the motor throught the radio hole and man the bottom screw is a trick to get a socket to stay on, any help there?

Will w.

garync1 · 03-04-2007, 07:56 AM

Quote:

Originally Posted by kc8avv

Hey guys, I have the same problem with my '99 and after talking to the parts guys at the Ford dealer, He told me it usually is the door that breaks and not the gears in the motor. I am looking for others who have dug into this and can prove/disprove, or find it is 50/50 in occurances.

I am trying to get into the motor throught the radio hole and man the bottom screw is a trick to get a socket to stay on, any help there?

Will w.

Yes on some models there was a prblem with the door breaking.. But as for getting to the lower bolts pull down the glove box. I am a thin guy so you may need to pull the bottom console loose if you have thick forarms.. I squeezed mine through the glove box area..

happymike · 06-11-2007, 05:57 PM

Just Fixed Mine ,i Changed Auctulator ,heard Clicking Noise ,no Heat , Cost Was Total 98 Dollars From Dealership, Now After I Changed Now I Have A Different Problem ,my Radio Dont Go On Also My Hand Held Transmitter Dont Work At All, I Disconnected Battery When I Was Installing Knew Unit As Not To Deploy Airbag Was Trying To Be Really Safe, Any Ideas What I Need To Do To Fix My Current Problem , Radio And Transmitter To Work Again Thankyou !

RickMN · 06-11-2007, 07:54 PM

Try this source:
DORMAN Part # 604203 HVAC Heater Blend Door Actuator
www.rockauto.com $31.79

Ed_Strong · 06-11-2007, 09:14 PM

When I ordered my Isolator Bolts and Upper Plenum Gaskets from Genuine Ford Parts.com to do the leckemby fix on my 2000 LX, I included the Blend Door Actuator for $32 in the order. I sure beats paying full price at the local dealer.
Have not installed it yet... might do it tommorrow!

churchfs · 01-15-2008, 09:09 PM

thanks for the info. this is for my 2001 windstar, exact same symptoms.

mechanicinabottle · 12-09-2008, 07:10 PM

for those of us on a tight budget , once you access the motor , turn your heat on or cold ( whichever your shooting for ) , and make sure the temp is all the way hot or cold. There's a small opening on the bottom of the motor that looks like a allen key bolt. Take a long screwdriver to it. Counter clockwise for heat and clockwise for cold. You will notice that the clicking will stop and you will have desired effect. ( remember , you must keep temperature control at full heat or full cold.....if not , you will trigger the bad motor and have to do it all over again. cheers.

Kmaag1234 · 10-13-2009, 07:08 PM

I was able to remove the blend in about 20 minutes. After my husband loaned me the tools. I can get the part a the deal for about $53.00. I am thrilled that I saved the cost of labor!

njlion · 10-19-2009, 03:42 PM

If you hear a clicking sound its the Blend Door Actuator. After I replaced mine, I took it apart and found a worn plastic gear, the rotating of which causes the clicking sound as it no longer meshes. To prevent this from happening in the future, don't slide the heater lever all the way to the right, stop just short.

dkc_2001 · 11-02-2009, 03:36 PM

I just completed it in several minutes. I pulled the radio and the dash and had plenty of room from the front and held the unit in place by coming in through the glove box access. I had to cut the car on to rotate the motor stem opening with a screwdriver to line it up. O'Reilley part number 604-203 for my '02 Windstar, $35.99.

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