Heater box actuator arm broken - ARGG!

My heater was not working because the arm inside actually broke. I first suspected the actuator so I removed it and tested it. I can tell you that replacing the box is both time consuming and VERY expensive. The best price I could get on a used box was close to $300 and it had to be shipped. The local reyclers said they did not carry them because of the time involved removing the box. A new one was out of the question and the labour involved to install is CRAZY! I did not want to remove it my self because of the engine coolant hassle, so this is what I did for all you out there that may have this problem and do not want to spend a grand fixing it: I removed all the screws on the box from the bottom. I had to remove the heater duct (plastic) that ran under the carpet in order to drop the box (bottom half) down enough to get my hand in there. I was able to get my hand in the box just enough to push up on the flap (valve). As I pushed up on it I jammed an extra socket wrench I had that just happened to have the same diameter shaft as the hole the actuator mechanism fits into. I basically was trying to lock the flap into the heater position and it worked. The only problem with this 'cheap' fix is the following: In the spring I will need to remove the tool to release the flap - not a problem because I can remove the radio and pull it out ot the actuator hole but in the fall I have to go through the whole process again (but I save money...woohoo).
This will be my last ford van for sure.

What year do you have??

What year do you have??


Mine is a 2000.:)

Guys! 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