Heater making a flapping noise

1999 Windstar - This site has bailed me out before and I'm back for another helping. When I turn on the heater there is a very noticable flapping noise comming from the heater. The temperature slide control for the front, if positioned in exactly the right spot, can eliminate the noise. In any case the front vents blow cold no matter what (the back works fine). Any repair ideas? Thanks in advance,
Hibouxj

http://www.automotiveforums.com/vbulletin/showthread.php?t=524247&highlight=Phordguy

http://www.automotiveforums.com/vbulletin/showthread.php?t=522563&highlight=Phordguy

NOTE: These are two different links.

It maybe your blend door motor 56.00 bucks I think for the part and you will need to pull your stereo not hard with the tool and your glove box down just push the sides in. The plastic motor gears teeth wear out there is so much lube on them you may not notice until you clean it off. What will happen is if you have heat now you wont have AC in the summer,door stuck on heat flow . Or if you dont have heat now you will not have it until you replace the blend door motor. the thumping sound is the gear missing teeth and the door is thumping to get to its stoping point. It cant get there because the gear missing teeth so it keeps going. to make it stop move the controls slowly until it stops may be in the middle hot or cold or all the way back to cold or hot.hope this helps.

I have the same flapping (clicking, I call it) noise in our 2000 Windstar.

Garync1 - are you saying it is the teeth on the moter that are likely broken... so replace the blend door Motor (is that the same as a blend door actuator?), not the blend door itself?

I'm mechanically declined but you make it sound like it could be a possible home-fix. What would be your estimate on how long this would take by an expert and also by a novice?

12 ounce: thanks for the links... a good start for me... but maybe not enough.

Does anyone like their Windstar? Ours has been nothing but trouble since 60,000 miles.

hibouxj - What was your final solution or resolution?

Yes the plastic gear teeth.The blend door actuator and the motor are the same. The dealer called it the motor and the part number called it the motor as well .. Not a hard fix. I have pics if needed.

Can't you just replace the gears on the motor? Don't they sell the gears alone so you don't have to buy the whole motor assembly?

Can't you just replace the gears on the motor? Don't they sell the gears alone so you don't have to buy the whole motor assembly?
I open mine up and yes if you want to spend time to try to find it you can most likley replace it. It looks like model airplane servo drive gears on some servos but getting the one that is the right size and teeth count can be tricky so i found out. Just easier to go to the dealer and get the motor. seems sad though a 1 cent plastic part.www.seattlerobotics.org/guide/servohack.html - 11k - the gears are a little like these on the inside. but do differ
I wish i could find the old part I would photo the parts.

Scroll down to the right and click on the pics to make them larger.
Hope this helps. The secret to removel of the radio is to push in the tool to you hear a click then push the tools toward the the drivers side and the other to the pasangers side door while you are pulling out the radio. There are snap clips were the tool goes in to that need to be pushed in. While you are pulling out. I think there are 3 bolts holding the blend door motor in and they are small. most of them can be accessed from the glove box area. A small 1/4 inch ratchet and extestion are needed from what i can remember... Sorry the pics are not that clear. The motor has a D shape shaft and slides in one way. hope this helps.. Gary
http://www.msnusers.com/FordWindstargroup/_homepage.msnw

could be a broken blend door. I found a kit that repairs the broken blend door problem with no dash removal and takes about an hour. The kit is called the HeaterTreater and they have installation videos on youtube. check it out: www.heatertreater.net