heater problems

[vivalasvegas777]

thank you all so very much for all your help in getting HEAT back into our vehicle. was looking at yet another costly repair and saw your comments, suggestions, and insight on this site and i fixed the actuator myself for under 60 bucks. you all answered our prayers. it was gonna be a COLD winters drive because 1k is NOT in our budget for repairs.
thanks again.
i did attach a picture of the inside of the actuator where the "gear" (ha ha ha) is missing it's teeth. not sure how well you will be able to see it but i guess there's not much to see anyway since they are MISSING.

[kerk]

I just replaced my actuator as well. Thanks to this thread, I was able to do it myself but the cheapest one I could find for a 2001 Windstar was $150. The Dealer wanted $450!

[12Ounce]

You may have automatic temperature control. ??

This feature was not available in '99.

[kerk]

Nope, no auto temp control. I have the regular hot/cold knob. And inside the only thing wrong was the little reducer gear. What a rip!

[12Ounce]

I'm gonna check the price at my dealer in a couple of days. $150 sounds "double" or more ...

[kerk]

Too bad I couldn't just buy that one little gear. Somebody must sell gears like that????? Any ideas?

[windcrap]

I am soo Glad i found this site and this posting.
I hate my windsatr but i do have to get things wiorking properly before I dump it on someone else My heater and o2 sensors are giving me greif now. Yhe clicity thump thing.

[blue jimmy]

I just want to thank everyone who took the time to post the problem and the repair. I want to tell whoever is in the same predicament what I did to get heat. After reading everything on this forum about the problem:
I removed that plastic cubbyhole below the radio and a metal frame under it.
I then was able to get at the actuater and remove it.
I took it apart and sure enough the small gear was chewed off on one side.
I took the plastic piece that has the gears on it that turns to open the door and removed it from the actuator.
I took that piece and stuck it in the hole that it goes in when it protrudes from the actuator.
With that piece in place, I was able to put the fan on and then turn that piece to the left to open the door and get heat.
When you turn the fan off the door closes, so it's not a permanent fix, but it will do until I find the part.
To make it a little easier, I took the piece out again and drilled a small hole in one corner, put a heavy twine through it and now am able to control the heat while driving.
I went to one garage, and the guy said he would have to remove the whole dash board. I'm on social security, see ya later.
Thanks again for the help guys.

[thscott]

Newbie here with a 1999 windstar with no front heat.

In attempting to solve this problem, I've followed this thread closely.

I got to the point of removing the white blend door actuator unit.

Peering into the 1/2 inch hole in the plenum that the white rotating actuator shaft goes into, I do not see much of anything. I certainly do not see a "D" slot to turn manually.

Is it possible that the blend door itself has fallen into the plenum?

In summary, I have the actuator motor out, but am not sure what to next shor tof taking it to the dealer and paying big bucks.

[12Ounce]

Thscott, I'm almost 100% sure that you have a broken blend door.

If you do searchs here, you will find that some of us have done a c-section on the plenum ... removed the door pieces, repaired, replaced. Costs less than $20 for the DIY'r (who already has a rotary grinder).

[thsu]

Hey guys:

I have a 99 windstar which seems have the exact same problem. However, I was not able to get the radio unit out even with the ping tool. It seems that the radio unit is stuck there no matter how hard I tried.

Did you guys run into the same problem? Or, there is something that I should be aware of.

Thanks

thsu

[thscott]

Originally Posted by thsu

Hey guys:

I have a 99 windstar which seems have the exact same problem. However, I was not able to get the radio unit out even with the ping tool. It seems that the radio unit is stuck there no matter how hard I tried.

Did you guys run into the same problem? Or, there is something that I should be aware of.

Thanks

thsu

The radio came out easily once I bought and used the correct removal tool at WalMart. I initially tried doing it with cut coat hanger but had no success. Even with the radio out and the AC/Heat controller out, it's still not easy to get at the blend door actuator as it is behind a metal bracket that I could not remove.

[wiswind]

Buy the little "U" tool for the FORD radio...it has little "knobs" on the ends.....also....wiggle things around a bit...if it does not come out. I seem to remember the instructions on the package for the tool said to kind of place pressure on the "U"'s sticking out......in toward the center....or out away from the center......Can't remember which (sorry!!!)
Also....if the radio seems stuck....try pressing in on it......to free the clips...in case there is an outward pressure on them......

[kerk]

I have taken them out with both a coat hanger and with the "U" tool. It is much easier with the "U" tool. I got it at AutoZone, took 5 seconds to get the radio out.

[blue jimmy]

Originally Posted by thscott

Newbie here with a 1999 windstar with no front heat.

In attempting to solve this problem, I've followed this thread closely.

I got to the point of removing the white blend door actuator unit.

Peering into the 1/2 inch hole in the plenum that the white rotating actuator shaft goes into, I do not see much of anything. I certainly do not see a "D" slot to turn manually.

Is it possible that the blend door itself has fallen into the plenum?

In summary, I have the actuator motor out, but am not sure what to next shor tof taking it to the dealer and paying big bucks.

I first took that actuator to a couple of parts stores and they didn't even know what it was. I haven't tried any dealers yet, so I have no idea what it cost. But I live in Massachusetts, and it's very cold here right now.

I took the actuator apart and removed the piece that has some gears attached to the end and the other end has a shaft that goes into that hole when it is installed. With that piece, I'm able to turn that door inside to get heat.

The problem with that is, It's hard to reach, and you can't do it when you're driving. The other problem is, the door will only stay in place when the fan is on, so when it gets to hot in the car and you turn the fan off the door goes back to its position.

What I did to get a temporary fix is drill a small hole in one end of that white piece and attach a strong piece of twine so I can pull it to get heat.

This is crazy, but you do what you have to do. Good luck with the part replacement. If and when I find one, I will post the cost.