A/C Blend Door Replacement

[cob206]

I have a 98 Taurus SE with that is having a Climate Control problem. The temperature control doesn't work as a constant temperature of air is always blowing no matter what it's set to. I've been researching the issue and have concluded the secondary blend door needs replacement. This is based on a Ford TSB on the subject and an error code thrown when running the EATC self test.

Anyway, my question is, how painful is it to pull the dashboard as that's what's required to access the plenum where the door is located. Anyone done this before?

[mastermech]

pulling the dash is quite involved you have to remove the center console, the heater control assembly, drop the steering wheel, remove the plastic trim around the windshied, remove the dash screws just to mention a few things. if you got an error 024 or 025 that is the blend door motor that went bad ($57.00) at ford, you'll need an ignition wrench 6mm (if I remember correctly) to remove the four screws mounting the motor to the housing. look at a haynes or chilton repair manual.

[mastermech]

pulling the dash is quite involved you have to remove the center console, the heater control assembly, drop the steering wheel, remove the plastic trim around the windshied, remove the dash screws just to mention a few things. if you got an error 024 or 025 that is the blend door motor that went bad ($57.00) at ford, you'll need an ignition wrench 6mm (if I remember correctly) to remove the four screws mounting the motor to the housing. look at a haynes or chilton repair manual.

[cob206]

Thanks for the response. I did in fact get a code 24. What's interesting is now that I've run the diags a couple of times, things have started working again and now the diags run error free. So, I'm more conviced it was a stuck Blend Door. I'll wait until it fails again before I change out the door.

[mastermech]

here are some codes that will help you narrow the problem down.

024 Fault in blend door calibration during self test
025 Intermittent fault in blend door calibration
030 Automatic temperature control sensor shorted
031 Automatic temperature control sensor open
040 Ambient sensor shorted
041 Ambient sensor open
042 Ambient sensor intermittent short
043 Ambient sensor intermittent open
050 Sunload sensor shorted
052 Sunload sensor intermittent short
115 Intermittent engine coolant temperature signal
125 Intermittent vehicle speed signal

the blend door was and continues to be an issue for ford.

[Blue_Twisted_Steel]

This seems to be a very popular problem. Book time to repair is pretty lengthy from 2.3 to 4.1 hours, depending on which vehicle. Once the car is warmed up, mine heats the vent or A/C air 24 degrees above the temp of the air comming into the HVAC system. It seems to go away now that daytime temps are lower than they were in summer.

Here you go. Sorry, but illustrations do not show up........

Article No.
02-23-6

Dated 11/25/02

CLIMATE CONTROL - ERRATIC OPERATION OF THE
COOL/WARM FUNCTION OF THE TEMPERATURE
CONTROL SYSTEM - REPAIR PROCEDURE FOR
STRATIFICATION (SECONDARY) TEMPERATURE
BLEND DOOR

FORD:
1996-2003 TAURUS

LINCOLN:
1998-2002 CONTINENTAL

MERCURY:
1996-2003 SABLE

ISSUE
Some vehicles may exhibit constant warm air discharge from the climate control system. This may be caused by the Climate Control Stratification Door (Secondary Temperature Blend Door) which may distort and bind.

ACTION
Replace the Climate Control Stratification (Secondary) Temperature Blend Door with a redesigned service part. The service procedure has changed as this door is now available separately versus replacing the case assembly.

SERVICE PROCEDURE

System Conditions
EATC System - EATC diagnostics may show a code B1249 or codes 022, 024 or 025. System defaults to full heat. System operates normally after running EATC on-demand self test, no concern found after performing appropriate Work Shop Manual Pin Point Test. Concern may repeat after two or more weeks.

Manual System - System has no temp control, possibly "popping" noise when changing temperature setting.

Stratification (Secondary) Temperature Blend Door Replacement

1. Remove the Instrument Panel. Refer to the appropriate model year Workshop Manual Section 501-12.

2. Remove the Temperature Blend Door Actuator. Refer to Workshop Manual Section 412-04.

3. The door control should now move freely. (depending on the extent of door interference, the door may not be able to be moved freely).

4. Inside the plenum, you will see the Stratification (Secondary) Temperature Blend Door or upper door attached to the main temperature blend door by an internal white nylon link. Disconnect the nylon link from the stratification door. Squeezing the clips together on the white nylon link should aid in removal (Figure 1).

5. Reach inside and remove the stratification door. Cutting the door with metal snip pliers near the pivots will provide easier removal.

6. Place the new door 3F1Z-19D842-AA inside the plenum chamber and slide in the large pivot point first (which is closest to you) then slide the door into position until the small door pivot point on the front side of the case clicks into place.

7. Connect the nylon link, reinstall the temperature blend door actuator, and instrument panel per the Workshop Manual.


Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME

022306A Replace The Secondary 2.3 Hrs.
Temperature Blend Door
(Includes Time To Remove
And Install Instrument
Panel) 1996-1999
Taurus/Sable

022306B Replace The Secondary 3.0 Hrs.
Temperature Blend Door
(Includes Time To Remove
And Install Instrument
Panel) 2000-2003
Taurus/Sable

022306C Replace The Secondary 3.5 Hrs.
Temperature Blend Door
(Includes Time To Remove
And Install Instrument
Panel) 1998-2000
Continental

022306D Replace The Secondary 4.1 Hrs.
Temperature Blend Door
(Includes Time To Remove
And Install Instrument
Panel) 2001-2002
Continental

DEALER CODING CONDITION
BASIC PART NO. CODE
19D842 42

OASIS CODES: 208000 208100, 208200, 208999, 290000



REMOVAL Heater Core/Evaporator

Prepare the vehicle for heater core and evaporator core housing removal.
1 Recover the refrigerant.
2 Remove the instrument panel.

Remove the right side cowl vent screen

Remove the screws and the water shield.

Disconnect the vacuum supply hose.

Using suitable hose pinching pliers, clamp the heater hoses. Disconnect the heater hoses. Cap the heater core tubes.

Disconnect the evaporator outlet spring lock coupling and cap the evaporator outlet tube and the suction accumulator tube.
During installation, install new O-ring seals lubricated with PAG oil or equivalent.

Remove the two bolts.

Disconnect the evaporator inlet spring lock coupling and cap the evaporator inlet tube and the condenser to evaporator line tube.
During installation, install new O-ring seals lubricated with PAG oil or equivalent.

Remove the three nuts at the dash panel.

Remove the screws and the heater outlet floor duct.

Remove the bolt and nut.
Remove the heater core and evaporator core housing.
INSTALLATION

To install, reverse the removal procedure.
Lubricant the coolant hoses with coolant hose lubricant or plain water only, if needed.
Evacuate, leak test and charge the A/C system.
Refill the cooling system.