Blend Door Actuator – 2000 Windstar

[Dan66]

Hi folks,

First post on this forum! I'm usually over at vintage-mustang.com, and decided to use my handle from there...

Problem is with the family truckster: a 2000 Windstar. No heat from dash unit, and a clicking sound when sliding the thermostat lever. Someone on my Mustang forum advised me it's probably the blend door actuator. So I thought I should find a more appropriate forum to look for advice.

I've heard it's a common break but a somewhat complicated repair... I'm hoping someone here has some photos or at least information about this repair. Where is the actuator located in a 2000 Windstar? Can I access it from the glovebox opening or do I have to remove the whole stereo/climate control panel?

Any info or advice is greatly appreciated! Thanks in advance...

Dan66

[osprey]

Dan66,

Looks like I may the same 'blend door actuator' problem on my 2000 Windstar. Removal of it looks to be a real bear...any suggestions to simplify its removal/replacement?

[John_Texas]

You can replace the Blend door act. by removing the Radio and look for the white plastic box, 3 screwa and 1 wire plug later you have it off, 5/16 small wrench will do the trick, New one from Ford is about $45.00

[gl1000]

I just did this on my 99windstar and found that taking the temp controlpanel and bezel made the job a breeze. I used 18"of extensions on my 1/4 drive socket wrench and zapped them right out. My unit was $53 from the dealer

Originally Posted by John_Texas

You can replace the Blend door act. by removing the Radio and look for the white plastic box, 3 screwa and 1 wire plug later you have it off, 5/16 small wrench will do the trick, New one from Ford is about $45.00

[silent meow]

I have had the same trouble with a 2000 modle and now my 2003,the blend door actuator assembly is pretty much identical on these two units,I remove the lower shroud,pull the cup holder assembly and while laying on the passenger side floor on my back simply use a 1/4 drive ratchet and an 8mm socket to remove the 3 screws. With the ignition "on" slide the control lever to one side then the other the motor will either move smoothly both directions or it will click in one,or possibly both directions.At this point I recomend verifying free movement of the blend door,as on my 2003 I actually had a contol cable partialy inside the plenum interfereing with the door movement. The problem is the first and second driven gears break teeth off,usualy on the first gear,sometimes both...why these are still made of plastic I don't know,as they seem to break within 60,000 miles of use. Hope this helps

[fordvanman]

I just ran into this problem and am hoping it's just the actuator. I was having trouble finding it, but now after searching this forum, I think I can find it and check to see if it is working. Should I be able to turn the shaft by hand? If not, I'm not sure how to tell if it's the actuator or the door itself. Good thing I still have rear heat.

[silent meow]

Originally Posted by fordvanman

I just ran into this problem and am hoping it's just the actuator. I was having trouble finding it, but now after searching this forum, I think I can find it and check to see if it is working. Should I be able to turn the shaft by hand? If not, I'm not sure how to tell if it's the actuator or the door itself. Good thing I still have rear heat.

If it's the blend door motor,it will be a unit about the size of a deck of cards,usualy yellowish plastic housing. there is a small "square" opening in the shaft end facing outwards on its face.You will need to remove the lower facia/CD holder to be able to see it well,as it's right behind the ash tray. I tested by having the ignition "on" and moving the "front" slider for temp control back and forth.looking at the shaft during this action,the shaft end will either move clockwise/counter-clockwise or it may just make an audible "popping" sound and not move at all. If it's popping,put your fingers on the housing and you should feel the clicking. If you can manualy turn the shaft,you will feel the blend door swing back and forth,indicating the first driven gear is stripped...the unit is around $90 bucks,and no, you can't get the 2 cent plastic gear separately.

[fordvanman]

Thanks, I'll give it a shot.

[silent meow]

If you have any other questions,just send me a note! Good luck!

[fordvanman]

Bad News: It's not the actuator. I removed several screws and was able to drop the heater core down low enough to see the door. The door itself has broken where the actuator shaft connects to it. I was able to prop it open to allow for heat, but am going to replace the door as soon as I get one. I currently do not see a way to replace the door without tearing all kinds of crap out of there. Any ideas on a short cut? I am contemplating cutting then repairing some of the ductwork to allow for quick removal and re-installation. What's the best way?

[veerg]

sorry to hear about the bad news on the door. I can't help you as I have not done this repair. I had the problem with the actuator which I repaired last month with the help on this forum. The reason I am writing this is to ask you to write the step by step procedure for us after you have done the repair. I am sure many of us will have to do this sooner or later. Your experience will help.

[fordvanman]

While searching for a replacement door, I came across a repair kit on ebay for this problem that gives step by step instructions and materials to do this fix without removing entire dash. The kit includes a replacement door and pics. It's called HeaterTreater. I ordered the kit for $120, and will post my results after performing the fix.

[12ringer74]

Had the same problem about a month back....
I used one of the multi-cutting tools from H.F. and cut out the hole similar to what Heater treater shows.....
I did not fork over the 120 bucks though... a piece of 1/2 aluminum tubing, some two part epoxy and a couple small pieces of fiberglass cloth, and voila..!!

I used a piece of plexi and some of the foil a/c tap to fill the hole.

[fordvanman]

Pretty clever. I just got the Heater Treater in the mail. Looks pretty good. Planning on getting started on it tomorrow. I'll post results in a new thread I think. _Blend Door Actuator_ doesn't quite fit what we're dealing with anymore. Wish me luck!

[12Ounce]

Here's another approach:
.
http://www.automotiveforums.com/vbul...light=phordguy