2003 Ford Explorer How do I replace the Blend

A heater core is a component inside the HVAC box (located under the dash) that is heated by engine coolant. Vent temperature is increased by routing air through the heater core before it comes out of the vents. The temperature requested by the HVAC control module determines how much air passes through the heater core and how much air bypasses it. This event is called air "mixing" or "blending" which refers to the hot air and cold air ratio. Air routing through and/or bypassing the heater core is carried out by the use of a blend door and blend door actuator. Over time these two components can fail mechanically which often results in abnormal noises and improper positioning leading to undesired temperatures. Now, higher-end A/C systems with dual-zone climate control have multiple blend doors and actuators; this is how how the two different temperature "zones" are achieved. A failure with only one of the zone's blend door/actuator would result in desired temperature out of one zone's vents and abnormal temperature out of the other zone's vents. You can read more here: https://www.yourmechanic.com/article/what-is-the-difference-between-climate-control-and-air-conditioning

First, insure you do not have a vacuum leak or bad vacuum check valve. If this is all good, you may have to change actuator and every model has a different way to access this--some require dash removal. If you must do this, get a shop manual as the air bags CAN BE VERY DANGEROUS!

Do you have Manual Climate Control System or Dual Automatic Temperature Control System ?
The temperature control switch:

• is a potentiometer that outputs a variable voltage to the temperature blend door actuator to set the position of the temperature blend door.
• initiates closing of the heater control valve. When set to full COOL, a lever on the temperature blend door pivot shaft depresses the pintle of the heater control valve vacuum switch. The heater control valve vacuum switch then applies vacuum to the heater control valve, closing off engine coolant flow to the heater core.
• is serviced only with the climate control assembly.

You may have disturbed something when changing the actuator , the vacuum switch o vacuum hose .

02 Ford Explorer Heat Blend Door Actuator Simple Fix - No ...

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www.youtube.com/watch?v=uvuPzf0wjEg
Apr 28, 2012 - Uploaded by broomballusba12 02 Ford Explorer Heat Blend Door Actuator Simple Fix - No Tools Needed ... I will be making a few new videos shortly on the Ford Explorer, The Ford Expedition, .... This does Not Work on a 2002Ford Explorer Eddie Bauer.

There are electric motors that move blend doors in your dash board. The blend doors control the heat/cool ratios as well as the location the air will blow from. It's very common for the doors to break or the motor to fail and require replacement which can be costly.

If you need further help, I’m available over the phone at https://www.6ya.com/expert/justin_3ae27a9d61d6acd4

If your a/c is cooling at all...
you need to NOT check refrigerant
levels ANYMORE... Every-time you do that
you are venting it... out (creating other issues)... STOP.

YOUR description is indicating
blend-door actuator issues...

Parts are available... You will need to get
into your DASH to find which actuator is failing


Then BUY the parts below... (not expensive)
http://www.rockauto.com/en/catalog/ford,2005,explorer,4.6l+v8,1430690,heat+&+air+conditioning,heater+blend+door+actuator,10721

Click on the "INFO" button of each to see how they differ
and their applications...

Example:
hot/cold blend door...
More Information for FOUR SEASONS 37535

Real FACTORY+WORKSHOP+REPAIR manuals
will actually show you the BEST/FASTEST way to
open up your dash to test, repair or replace these parts.

Check out eBay or the internet
for REAL FACTORY repair manuals (example)

2005 Ford Explorer Shop Service Repair Manual XLS XLT Eddie Bauer Limited...

Hope this helps

Carnac the Magnificent

yes, common problem. Blend door actuator is stripping it's gears. Remove actuator and make sure door rotates by hand. If not remove heater box and repair door operation. If it moves OK by hand, replace the actuator. I don't have procedures for replacing yours, but follow the sound, removing whatever panels necessary to get to it. The part looks like the below pic and sits flat on the heater box with a cable coming out of it. Cost is about $35. Let me know if you have any more questions.

your blend door actuator gear is slipping. remove actuator and check blend door for free movement. If jammed, you may have to open the system to unjam. If door is free to moe, replace actuator. See procedure below to access blend door. Not sure you need a lift, as long as you can get the 2 nuts off under the truck.

Removal & Installation

1. Position the vehicle on a hoist with the gear selector in NEUTRAL.
2. Remove the left-side quarter trim panel.
3. Remove the parts in the order indicated in the following illustration and table.

Fig. Blend door actuator - auxiliary

(1) Auxiliary line floor pan bracket nut (2 req'd)
(2) Auxiliary housing bolt
(3) Auxiliary housing bolt
(4) Auxiliary housing nut
(5) Auxiliary harness electrical connector
(6) Blend door actuator electrical connector
(7) Screw (3 req'd)
(8) Blend door actuator

To install:

1. Installation is the reverse of the removal procedure.
2. Observe the following tightening specifications:
   
   Auxiliary line floor pan bracket nut (2 req'd), 71 inch lbs. (8 Nm) Auxiliary housing bolts, 62 inch lbs (7 Nm) Auxiliary housing nut, 62 inch lbs (7 Nm)
   

Make sure you are getting plenty of vacuum to the control, if you are than it will have to be replaced.