No heat 97 Windstar

[loubega]

I want to thank all of you who post information in this forum. Because of ya'll I was able to avoid a major repair bill. I spent $5.00 and two hours fixing a problem that Ford wanted $1,000.00 to fix.
Problem: No heat in my 97 Windstar
Clues: Creaking noises coming from behind the radio area when selecting temperature.

What I did: Check thermostat-OK, check heater core-OK. Advice from ya'll, check heater air blend door motor-Not ok. This was a white box, approx. 4X4X0.5 inches located on the heater. To inspect you'll need to remove the cassette storge compartment. When actuated the shaft for the motor was spinning freely in the shaft of the door and not moving the door. Motor tested fine against load, not jumping teeth. Blend door moved freely when tested using a screwdriver to open and close the door.

Repair: Many of you suggested removing the radio ($5.00 for the tool). I found it much easier to remove the cassette storage compartment-4 screws and then the metal frame for the compartment 2 bolts and 4 nuts. Removal of the ash tray/cup holder will make the job even easier but is not necessary. Pieces of the plastic shaft on the door had broken away. I drilled a 1/8 hole across the shaft of the motor. Using a bench grinder I shaped the head of 10/32 screw to fit the area of the broken door shaft and screwed into the motor shaft. JB weld, super glue, thread repair fitting are other possible methhods of repair.

Hope this helps someone.