You’re welcome! It’s amazing how a little bit of epoxy can make all the difference in the world. Thanks for watching!

Chuck Colvin Ford in McMinnville Oregon I had to go in and get a cost on a the hot/cold air actuator for the cabin temp they told me that it would be $950.00 to put that part in, I told them what I needed fixed and they told me that wasn't the problem and refused to send someone out there to take a look at what needed to be fixed. So I took it to another shop they looked at it and they gave me a cost of $45.00 to fix so for ($102.00 I got it fixed) $57.00 (for the part) and $45.00 (labor) They don't listen to the customers they think they know it all Customer service sucks That's why I will be going to Newberg Ford in (Newberg Or).

Glad I could help. Thanks for watching.

No problem! Definitely recommend keeping the fresh air door and allowing it to open and close. All the other guys I see screw it shut.

Did u put the filter back in or leave it out?

@@Plush-Freddys-Pizzaria I put it in the glove box at the time.

You’re welcome! Glad I could help!

No problem glad I could help

Thank you! Enjoy that cold air and max blower speed!

Great call! Mine was removed from previous rigging.

Thank you so much for this extra step, so much help

Thank you!

Thank you!

Awesome! Glad to hear!!

You’re welcome. Thanks for watching!

Thank you!! That means a lot to me! Glad I started making videos because I know there’s people out there in the same situation I am!

@@iamdjnam Same here. Your videos have helped me a ton.

Thank you!!!

@@iamdjnam 6666

Agreed

This is why I'm scared to check mine! Tbh idk these things existed even until now.

Thank you! Glad I could help!

I had to replace my radio/CD player for that

We had to replace our radio for that same issue as well.

Excellent idea! Didn’t even think to melt the plastic. That must’ve been a nice clean cut! Thanks for watching!

It's easier to just make a flap on the front. Remove the two screws, they are 8mm heads, then cut a little outside of the screw lugs. The plastic is soft, my short-blade lockback knife did the job. My big hand fit in there alright.

Update on today's fix - the swinging door is connected but the vacuum only moves it a little bit. There were some leaves on top of the fan, cleaned those out. Then I disconnected the vacuum to the door operator and plugged it, then stuck an unsharpened pencil through the narrow air intake above the "new door" and zip-tied it in place to hold the swinging door shut, with the eraser contacting the door. No outside air coming in now.

Also noticed that the door operator arm for the main vents in the middle was broken so I opened it all the way and wedged it in place with stout foam; disconnected the vacuum to that one also.

Thanks for the feedback and watching! :)

Appreciate you 💪🏻

For sure definitely the right time to fab up a custom cabin air filter

Good deal. Didn’t think of that.

Blend door problems are just the start. Their shotty 5r55 transmissions, non metal reinforced timing guide in the back of the engine, failing rear differentials, etc etc

Glad I could help. Thank you so much for watching. Any questions just let me know.

Much appreciated thank you

Thanks!!

For anyone who had the c-shaped clip break on their hinge piece... I was able to get the door hinge epoxied back on but I was worried that the peg that sets in the actuator arm may fall out eventually without the c-clip. I got a metal brake caliper slide from a recent brake change (any small flat piece of metal), hammered it flat, and cut it down to ~dime size with a Dremel tool. I then used increasingly larger drill bits to increase the size of the hole until it was barely able to slide onto the "peg" portion of the hinge. (you can hammer increasingly larger nails through it as well). I had to twist it on. You can put a bit of epoxy on the piece before you twist it on. My backup plan was to find a shallow nut that would fit snugly and epoxy it on. If the peg ever breaks, I will probably drill it out and use a bolt, nut, and washer to secure the arm to the hinge.

So many people ask for that. I may just have to make one! Stay tuned. :)

I will subscribe and hit the 🔔 . Thanks for your time & effort.

You’re welcome!

Couldn’t find just the clip, looked everywhere.

Where did you get the clip?

💪🏻

Dang! I honestly had no idea, thank you for letting me know! Oh well, next time I fix one I will know to undo the screws. Thanks for commenting!

Brian - Thanks for adding your comment, saved me from hacking up my Explorer. I removed the 2 screws but it seemed the "door" was possibly glued shut at the bottom, would not easily swing up. I saw 2 other screw I could not get to, one on either side, so I made vertical cuts with a Dremel tool just outside the location of each of the 2 screws I did remove, then used a very sharp screwdriver to pry to "vent door" at the bottom edge and it opened. I only extracted the fallen door for now since I was working in 34 degree weather, did not glue the actuator hinge. That's good enough for now. I get both outside air and cabin air but that's fine, the heat is blowing like brand new!

​@@alansolomon9601 Hey Alan, Guess what, In my post I forgot to say to use a razor knife or as you used a dremel tool to make vertical slits and THEN it becomes a hinged door...it appears that the engineers at ford created a hinged opening on later models. Glad you figured it out on your own. If you want really warm heat in your suv you had better shove a shirt or rag into the fresh air intake vent from inside the engine compartment until you can get the flap set in there...I don't think you will be very happy with the heat with the vent open in cold temps! You would not believe the PAIN I went through to repair the actuator arm and re-install the flap! and I could not find a replacement part..it seems that if you want the actuator arm you must buy the entire housing unit for the blower! I am so thankful that these folks posted their video on this problem, it literally saved my suv from the scrap yard. After fixing it I went ahead and detailed the hell out of it, new tires, new muffler system ($1500) they have 3 cat converters on the exhaust. Now I have great heat and air-condition! Mine is a 2002 Mercury Mountaineer Premier with the silver birch paint and leather interior.

Timing is everything, have a 04 Limited disassembled, and was just about to cut to have access to reassemble. Thank you for posting this, as a little heat applied, and the sucker right popped open!

Glad I could help. Thanks for watching.

I agree.. I thought it was Chris Fix for the first minute or so.

So many people say that. We actually live one town over from each other.

Absolutely not an easy fix

That little plastic clip on the trans is definitely a breeze to do. I just didn’t wanna bust my back pulling the dash and I’m sure the 100k other people who watched this video don’t want to either lol

Hey bud! Such a common problem on the explorers. Check your filler neck, there’s a purge valve to allow air out and gas in. If it’s collapsed, the gas will continually click off like that.

Behind the plastic cowl near the wiper blades is a sealed little access hole. That’s the corridor where rain water gets diverted to the ground from under the windshield. In that corridor, you will see the fresh air inlet (kinda looks like a box with grid). You can stick your hand in there and stuff a shirt in the opening. Mice won’t be able to get to it, so you’re good on that. Thanks for the sub!!!

@@iamdjnam Thank you, again. I removed the black cowl, but didn't find the vent. Could you be a little more specific on the location of the vent. Do you need to remover the cowl?

You need to remove the entire cowl. Then underneath there is this factory sealed and glued grommet/cap. Approx 6”x8” long. Cut the glue away and you can open it up.

I left it open and noticed no difference whatsoever in air flow.

kzfaq.info/get/bejne/hq2RnbNz3bW6Z4U.html

Nope you have to put the door in and then slide the hinge into place.

There is no cabin air filter. The Explorer never came with one. You can custom make one and slide it in the air box that we cut open.

No.

It does not.

You can’t. They don’t sell it.

Nope. Leave it open.

The vacuum line is disconnected at the actuator so it doesn’t matter what position the AC knob is on.

@@iamdjnam Thank you. What would you recommend if the "lever" arm/piece is totally missing. Id rather not buy the whole duct/inlet. I thought about just taping the door over the opening so it is always closed off.

Remove blower motor and net

You can remove the whole blower assembly. It’s held in by a few little screws. Will give you the chance to clean out whatever fell in. You don’t need to if you don’t want to. It won’t hurt anything.

@@iamdjnam perfect. Thanks so much for getting back to me in still in the middle of cutting out that plastic lol

The actuator is held by 2 screws. The hinge just hooks onto the actuator.

Yup yup

Nope you do not need to fix it. That box is air inlet, it pulls air in. Doesn’t blow it out. This procedure will actually increase air flow from your vents.

Platinum Garage Sweet man thanks, tons of help!

I do not, but I will tell you this.....they don’t sell just the hinge. I looked everywhere. You have to buy the whole damn air box assembly.

Platinum Garage thanks 👍🏼will it work in position with super glue ?

Yes! Super glue is perfect.

That is an air inlet. Not outlet. The motor doesn’t blow that direction. I left the window open.

@@iamdjnam Thank you for the prompt reply. Do you know what the technical name for that part that you cut into is?

Air inlet duct. Ford (1L2Z-18B259-AC).

@@iamdjnam Thank you very much!

C T Before I fixed the door I put shirts in there to prevent cold air from coming in during the winter.

Platinum Garage Oh okay. Thanks for the reply. Does this fix help the back AC as well?

Yes it does!

Platinum Garage Thanks!

Located under the hood behind the headlight. There is no cabin air filter.

On the ranger I think the blower is under the hood. You can take out that blower motor and vacuum out the leaves behind it. I did the same thing on my F250.

Platinum Garage It worked! It was tough getting 20 year old leaves out of there. I had to scrape with my fingers and repeat. Scrape, vacuum, scrape and vac and it's perfect! Thanks brother!

Awesome!! Happy to hear it worked!!

Left it open

Nope leave it be you’ll be perfect

@@iamdjnam thanks bro

I don’t believe so, although it’s worth looking into.

Blend door actuator or loss of vacuum to the cabin

No. Expedition doesn’t have this issue.

What gets pulled in? The belt, or the tensioner? Check your harmonic balancer. It’s a two piece design that fails, splits, and starts to cause all sorts of problems.

@@iamdjnam a quarter of the whole serpentine belt sucks into the fan clutch

Definitely check the harmonic balancer. Also take the belt off and spin the compressor and PS pump by hand. See if anything is binding.

@@xxdeathreaperxx2024 also check if the tensioner out isn't pulley is bad.

Under the cowl is an access panel by the passenger side wiper. Beneath that panel is the channel in which rain water drains that runs down the windshield. You will see the fresh air inlet, that’s where I put the shirt.

Thank you! Appreciate it. I will have to try when I get home. Didnt see it last night.

I know...

Yes, but it's not big enough to put your hand in.

Hey man! My trailer has been snowed in lol I haven’t had a parts truck in over a month. I usually sell my engines for $500 next time I have one I’ll hit you up!

@@iamdjnam kool

Click on my channel, I posted a part 2 video explaining it

@@iamdjnam what happened to the part two? I watched it before and it's no longer there?

You would constantly be bringing in outside air. If you live in cold climates you will feel ice cold air in the winter entering behind the glove box.

@@iamdjnam is the door usually open unless I have max ac selected? Thanks for taking the time to answer my questions

@@austinmike6046 yes the door is usually open but in such a way that prevents cold air from being noticed. It only closes on Max AC

@@iamdjnam great, thanks for the help!

VtEc LoL

It bolts to the top of that plastic box on the left side. If you reach your hand up to the left you will feel it. You’ll get a better view once you chop your way in and remove the broken door. Also, there is a little metal bracket directly behind the glovebox I recommend removing for better clearance.

@@iamdjnam well I cut into the heater box removed the door felt up to and couldn't find anything just a hole i could put my finger into and touch the other finger on the outside of the housing I couldn't feel anything else.

Wow that’s strange! There could be a chance the entire actuator and hinge was removed by the previous owner. If you stick your hand in the box and go to the top left, there should be a pivot hinge like shown in the video.

@@iamdjnam i don't think so. I'm the 2nd owner and I've had it for about 15-16 yrs and it was working when I got it. Ac didn't work for a few years and I'm just getting to it replaced hose and fuses was working really well then door fell now trying to figure this out.

The condenser is in front of the radiator behind the grill. It's definitely not screwed to the condenser.

Hey if it works it works

It pulls out and pivots off of the actuator. You can remove the 2 8mm bolts that holds the actuator on to help. It’s quite simple once you get the hinge on, the door only fits one way.

Platinum Garage now It won’t close any ideas with that? I got it back on and glued but it stays open

Matt Roberts did your little vacuum hose pop off? It will only close with the car running.

Platinum Garage I had to start it haha. Thanks man you’ve helped a ton!

Nope!

@@iamdjnam damn thanks my dad has a sport trac and I was trippin lol

You can drop the blower motor and go in from there too. But you can’t get the door out that way. The only other way is to remove the entire dash and replace the whole thing using the $150 kit. As far as other stuff goes, wd40 to fix the door ajar light, and zip ties for the blend door when it breaks.

@@iamdjnam thanks for the quick reply. Yeah I'm not trying to replace the whole thing. I'm not even sure if it's loose TBH the air just doesn't seem to be that cold so I'll take a look at options A and if that's too annoying I'll cut it open. The door ajar thing happened the first month I got it, that was a fun surprise

@@iamdjnam WHERE do I put the WD40 for the door ajar light? I look like a nut running around the car opening and slamming the doors all the time.

Email me using the address in the description and I will send you a pic

Gotchu man thanks for watching!

I live next town over from him lmao

There isn’t one. You can size one up and insert it where we cut the plastic box out, over the blower motor.

Just wondering ive got the single overhead cam 4.0 L 2003 never looked into it

Under the hood by the radiator hose at the top

@@brianbroadwayjr6312 that’s the engine air filter

@@iamdjnam u right lmao