1993 Lincoln Town Car Logo
a
ardell whitwer Posted on Mar 09, 2014

Heater blend door dash plenum

Have replaced blend door after pulling dash way back and clicking sound of broken plastic gear is fixed and now have both heat and air conditioning only problem now is defroster works and floor flow works but the dash air vents do not get any flow I have looked at exploded view of plenum and it looks like the vacumn control is the far left one with yellow and red lines to it but have access problems to get to it do I have to pull dash again to get to it ???

1 Answer

A

Anonymous

Watch You Tube Video & see what has to be done

5 Related Answers

motor1258

Mike Butler

  • 6674 Answers
  • Posted on Dec 13, 2008

SOURCE: sometimes heater will blow cold

Clump sound is probably the blend air door inside housing moving to where it's supposed to be. Is that when you notice it heating like it should? Try to pay attention when driving to see if you hear that "clump" noise or feel different temperatures as you accelerate, and then let of the gas, which would indicate vacuum operation of blend air door, and tells you that there is a vacuum leak somewhere in the system, or a perhaps just a faulty check valve in the line somewhere. let us know.

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Anonymous

  • 10 Answers
  • Posted on Feb 07, 2009

SOURCE: have 1996 lin towncar where n how 2 fix blend door 4 heat n a/c

In order for the blend door actuator to be replaced, the dash must be removed from the vehicle.

Anonymous

  • 783 Answers
  • Posted on Mar 20, 2009

SOURCE: My 2004 v6 lincoln ls air conditioner freezes up

One of 2 problems,either the system is low on freon or most likely the problem is a bad evap temp sensor. This vehicle does not use a cycling switch to cycle compressor on and off like a conventional system does but instead measures the temp at the evaporator core itself.

Pablo Gonzalez

  • 733 Answers
  • Posted on Sep 19, 2009

SOURCE: 1997 Lincoln Town Car; nothing but heat

check your vaccum lines behind the dash. if you find the one that goes to the blend door, put some vaccum on it and see if it opens and closes for you. if not, then yes, your blend door is broken. if it closes, check your temp control gauge.

Anonymous

  • 1 Answer
  • Posted on Mar 04, 2010

SOURCE: 1994 lincoln town car, almost no heat, blend door

I had the same problem no heat or very little heat. my garage found the problem to be up under the dash something to do with the heatting door stock open try checking under the dash.

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There is a continual clicking sound when in motion

If it is in the dash it is the AC/Heater automatic air temperature control blend door actuator that is makeing noise due to a jammed/warped or slow moving blend door.
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Heater wont work, fan runs, but cant chamge temp 2001 F150 SUPERCREW 5.4

Do you hear any clicking or popping noises coming from dash area when you try to change the temperature? If so, you have either a bad blend door actuator or a broken blend door. If it's just the actuator, you can find it by following the popping noise to the location. It is under the dash close to the passenger's side of the vehicle. The actuator is easy to change once you find it. If the blend door is broken, you will have to pull the dash out and remove the air plenum from inside the dash to gain access to the blend door.
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Need to replace heater core? how do i remove old one and replace new one?

Here are the instructions with a diagram. If you need to enlarge the diagram save it to your picture files and then enlarge it there.

1. Disconnect battery ground cable, then drain cooling system. See: Engine, Cooling and Exhaust\Cooling System\Service and Repair

2. Disconnect heater hoses from heater core. Plug heater hoses and core fittings to prevent coolant spillage.


3. Remove bolt located below windshield wiper motor, attaching left end of plenum to dash panel.


4. Remove nut attaching upper left corner of evaporator or heater case to dash panel.
5. Disconnect vacuum control system supply hose from vacuum source, then push grommet and hose into passenger compartment.

6. Remove all instrument panel retaining screws and pull instrument panel back as far as possible without disconnecting any wire harnesses.
7. Loosen right door sill plate and remove side cowl trim panel.

8. Disengage temperature control cable housing from bracket on top of plenum. Disconnect cable from temperature blend door crank arm.

9. On models w/Automatic Temperature Control (ATC) , remove cross body brace and disconnect wiring harness from temperature blend door actuator and disconnect ATC sensor tube from evaporator case connector.
10. Disconnect vacuum harness at vacuum connector near floor air distribution duct.

11. Disconnect white vacuum hose from outside recirculating air door vacuum motor.
12. Remove two hush panels.

13. Remove one plastic push fastener retaining floor air distribution duct to left end of plenum. Remove left screw and loosen right screw on rear face of plenum. Remove floor air distribution duct.

14. Remove two screws from rear side of floor air distribution duct to plenum. To remove right screw, it may be necessary to remove the two screws attaching lower panel door vacuum motor to mounting bracket.

15. Remove push fastener attaching floor air distribution duct to left end of plenum, then remove floor air distribution duct.
16. Remove two nuts located along lower flange of plenum.
17. Carefully move plenum rearward, so that heater core tubes and plenum case upper stud clear openings in dash panel, then remove plenum from vehicle by rotating upper portion of the plenum forward, down and out from under instrument panel. It may be necessary to carefully pull lower edge of instrument panel rearward while plenum is being removed from behind instrument panel.
18. Remove retaining screws from heater core cover, then the cover from plenum assembly.

19. Remove retaining screw from heater core inlet and outlet tube bracket.


Heater core removal and installation diagram.




emissionwiz_78.jpg

20. Pull heater core and seal assembly from plenum assembly.
21. Reverse procedure to install.
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Do i have to remove complete dash to replace a heater core in 1992 grand marquis.

Section 12-03: Air Conditioning System 1992 Town Car/Crown Victoria/Grand Marquis Workshop Manual REMOVAL AND INSTALLATION Plenum Removal
  1. Disconnect battery ground cable.
  1. Disconnect the heater hoses from the heater core tubes. Plug the ends of the heater hoses to prevent coolant loss.
  1. Plug heater core tubes securely to prevent coolant leakage from heater core during plenum removal.
  1. Remove three nuts located below the windshield wiper motor retaining the LH end of the plenum to the dash panel (Fig. 15).


FIG. 15 Plenum and Air Inlet Duct Removal


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  1. Remove one nut retaining the upper LH corner of the evaporator case to the dash panel.
  1. Remove LH and RH lower instrument panel insulators.
  1. Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment.
  1. Remove all instrument panel retaining screws and pull the instrument panel back as far as possible without disconnecting any wire harnesses.
  1. Loosen the RH door sill plate and remove the RH side cowl trim panel.
  1. On manual systems, disengage the temperature control cable housing from the bracket on top of the plenum. Disconnect the cable from the temperature blend door crank arm. On ATC systems, remove cross body brace and disconnect wiring harness from temperature blend door actuator and disconnect the ATC sensor tube from the evaporator case connector.
  1. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
  1. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
  1. Remove two hush panels.
  1. Remove one plastic push fastener retaining the floor air distribution duct to the LH end of the plenum. Remove LH screw and loosen RH screw on the rear face of the plenum (Fig. 14), and remove the floor air distribution duct.
  1. Remove two nuts from the two studs along the lower flange of the plenum.
  1. Carefully move plenum rearward to allow heater core tubes and the stud at the top of the plenum to clear holes in the dash panel. Remove plenum from vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull lower edge of instrument panel rearward as necessary while rolling the plenum from behind the instrument panel.
Installation
  1. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
  1. Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.
  1. Install three nuts on the studs along the lower flange and one on the upper flange of the plenum (Fig. 15).
  1. Install three nuts below the windshield wiper motor to attach the LH end of the plenum to the dash panel.
  1. Install one nut to retain the upper LH corner of the evaporator case to the dash panel.
  1. Position floor air distribution duct on plenum. Install two screws and plastic push fastener.
  1. If removed, position panel door vacuum motor to the mounting bracket. Install two retaining screws.
  1. Connect the white vacuum hose to the outside-recirculating door vacuum motor.
  1. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install floor duct.
  1. Connect the ATC sensor tube to the evaporator case connector on ATC equipped vehicles.
  1. Install the cross body brace and connect wiring harness to the blend door actuator on ATC equipped vehicles.
  1. Connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable as outlined under Adjustments.
  1. Install the bolt to attach the lower RH end of the instrument panel to the side cowl.
  1. Install the RH side cowl trim panel and tighten the RH door sill plate retaining screws.
  1. Install glove compartment door and check arms.
  1. Connect vacuum supply hose to vacuum supply.
  1. Install RH and LH lower instrument panel insulators.
  1. Install two hush panels.
  1. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
  1. Fill the cooling system with coolant to replace coolant lost during removal of the plenum.
  1. Connect the battery ground cable. Check the system for proper operation.
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There is a huge problem with the blend doors on the Ford Windstars. To access the Blend doors, the dash must be pulled and the plenum box removed. It is very labor intensive. Alternatively, there is a way to remove the glovebox, make an incision in the plenum box, and replace the blend door. There is more info on the problem here: http://www.heatertreater.net/Final%20Tech%20info.htm#History
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