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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!
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:
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.
replacing a blend door actuator is a tedious job. You have to remove the steering column taking xtra careful for the wirings. Complete removal of the dashboard, remove the instr. cluster, radio , glove box.Remove the console box, discharge the freon ,disconnect the heater hoses, ac hoses. After removing the dash you can gain access of the ac/heater phlenum. Remove the blend door actutor.bolts and screws are sometimes in a concealed location so xtra patience is needed.
This noise is the air temperature control blend door actuator motor, it has stripped the little plastic reduction drive gears, this is a common problem on Explorer and the Expedition, in order to change this motor u must remove the dash assembly, the blend door motor is in the approx center of the air distribution plenum between the heater core and the AC evaporator core.
This problem is caused by a defective blend door (stuck) or blend door actuator motor. The blend door is what moves in the air stream to supply heat or cool, or a blend of the two, it is in the dash and the dash must be removed to access it for repair.