ilsp43

No Heat! Fan works fine... AC works fine. OK...when you advance the heat lever you start to hear a "clicking" sound. It sounds like something is trying to engage and it is just not doing it. I took the bottom panel off the dash (under the stereo and heater panels) and could get a faint glimpse of what looks like a rod coming from the control panel area going into what looks like the heater plenum.

ok....after some research on the net it looks like i am into a blend door actuator/motor problem. i am asking if that sounds like a fair guess of the problem and how the heck you get at the parts/motor/actuator etc. i've seen articles where they tell you to cut a hole in the plenum....nah! then i've seen articles that make it sound like this is a chip shot to fix.

i'm pretty handy with cars and the like so repairs do not scare me but if the dash has to be removed that would be a first for me and kinda intimidating.

Any advice would be appreciated.

KimMG

Get a repair manual and read over the procedure. Removing or loosening the dash can be tedious. If you don't wish to purchase a repair manual, try your local library or go to the dealer parts counter when they are not too busy and buy an oil filter or something and ask the parts person if they will copy the appropriate pages from the factory service manual. You will need to find out why the actuator is not working, bad vacuum connection, or is it just sticking. Set the heater to hot and try working the door by hand if you can reach it to see if you can unstick the actuator.

rodeo02

Yep, it definately sounds like the electric actuator that works the hot/cold blend door could be the issue. The actuators are maybe the size of a deck of cards and will be plugged in with an electrical connector. I'd get under the dash & work the heater control so you can locate it by the sound. The actuators themselves are usually easy to r/r.

Joel

__________________
2007 Chevy Cobalt LS 4dr, auto
2008 Honda Odyssey LX chick magnet
Gone but not forgotten : 2001 Ford Windstar LX, 2005 Trailblazer LS 4x4, 2002 Isuzu Rodeo LS 4x4 & and many more.

Tomb stone

Hopefully, it’s just broken gears in the blend door actuator, which is fairly easy to replace. Worst-case scenario would be a broken blend door. If that’s the case, you’re going to have a nightmare getting it replaced. The blend door is in the plenum and is not sold separately. The dash will have to be completely removed to get the plenum out (that doesn’t look fun). Instead of replacing them, some people have repaired their broken doors by drilling holes in the plenum and screwing it back together (this is the repair you found during your research). You will probably be able to tell if your door is broke by removing the actuator motor and looking at the “D” shaped key-way the motor shaft engages into. Hopefully it’s just the actuator gears. I tool mine apart and half the teeth were broken off.
The reason they break is because the motor travels too far and applies way too much pressure on the door when it is fully closed. I noticed this when I was replacing mine. I had to forcibly twist the actuator (applying closing pressure on the “already closed” door) to get the new actuator mount holes to line up.
To prevent any future breakage (after you get it fixed), never slide the temperature control (on the dash) to its maximum stops. Leave it about ¼ inch from the end. Trust me, you wont feel any difference in the temp– and the motor wont be pressing down on the door.

I cant remember how much the actuator is, but its around $40-$60 at the dealer.
Here’s a pic of my broken one
TOM

caepperson3

hi im newto this forum and i just purchased a 2003 windstar with the exact problem have you fixed yours yet and what was the cure and price

FordBoss88

Same Thing happened to me. This is a five minute repair (if it is the actautor). Remove the radio (using removal tool), disconnect antenna lead and power lattice. Remove the lower shroud below the ash tray. You do not need to remove it as in disconnecting the extra power supply plug, but rather remove the for plastic screws and friction holders. Pull the shroud forward and to the left. Using an 8MM 1/4 drive socket, remove the top left screw and right side screw from the radio access hole. Pull out the ash tray and you can easily remove the bottom screw. Once the three screws are out, pull the actuator forward, but keep it plugged in and set to the side. Start the vehicle and set the climate control to Vent. Attach a 1/4 2" extension to the 1/4 drive and place into the D shaped opening of the Blend Door. Roll the
D-Shaped slot to the left for heat. If you are now blasted with heat, you have a faulty actuator. Once the climate control is set to "Off" the blend door will return to the cool position without the actuator. Now if you ar waiting for Pay Day (like Me), you can choose the position of the blend door while it is still plugged into its power source. If you want heat, roll over the the actuator arm to heat and then disconnect the power supply. The motor will stay locked in that position. Re-install (without power to the actuator), because you will need the actuator to hold the blend door open for heat. Replace the actuator on Pay Day. Very easy project!

JhanJo

Thanks FordBoss88, your post was a big help when I was troublshooting and then replacing the blend door actuator. The problem was exactly what others described, a clicking noise when you turned the temperature control to heat and it would only blow cold air.

You were a big help today, thanks!

happymike

actuator was my problem to, i just changed it,few teeth were broken off of the small plastic wheel inside unit, i was hearing a clicking noise,new unit cost full price tax included at dealership $98 dollars ,if this part was steel it still be working.

PLEASE IF ANYONE KNOWS I NOW HAVE A PROBLEM I CHANGED THIS UNIT ACTUATOR AND NOW MY HAND HELP TRANSMITTER DONT WORK AT ALL ,ALSO RADIO DONT WORK AT ALL, ANY IDEAS WHAT I NEED TO DO THANKYOU !

happymike

Hi My Van Is A 2003 Windstar Sport, And Since I Changed The Actuator ,i Now Have A New Problem ,it Is My Hand Held Transmitter Dont Work At All,also My Radio Dont Work At All !
Please Any Ideas I Sure Can Use Now Thankyou !

happymike

please help now!
what is radio code for 2003 windstar sport thankyou !

sandonf

this string of chats was very helpful. I just changed mine and it fixed the problem. Only thing I did different was I DID NOT PULL THE RADIO. I see this has been causing radio problems. Just take the bottom skirt off like stated above, PULL out the ash tray, not remove, and you should be able to reach all screws. it is a little tight but worth not having to remove anything.

boricua_daddy

have same problem but found a vaccuum line loose cant find where it goes its in the engine compartment any one knows any diagrams for my 2000 winstar

garync1

There are 2 small hoses that run into the back passenger of the upper intake. Very hard to see unless you have a flash light and look under the back passenger side corner of the intake plenum. It tucked right under the lower part 2 small lines.. I guess thats what you mean. For unhooked vac line..

wiswind

The HEAT, as in HOT or Cold air is driven by a electrical motor....driving a "blend" door.
The part in the picture is for this.

Where the air GOES is driven by vaccum from the motor.
With no vaccum, all the air will go to the defrost.....to the windshield.
But, the air will still get HOT when you set the temperature control to HOT.
Most common problem here is a vaccum leak....disconnected line or broken/pinched line.

__________________
1996 3.8L Windstar
Link to my pictures, intended as an aid, not a replacement for, a good repair manual. http://community.webshots.com/album/201931518cScpNK

boricua_daddy

i see the hose from the intake it goes from there 2 a tee & from the firewall 2 a fitting