2001 Ford Windstar Logo
Posted on Dec 26, 2009
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Blend door for front temp control is stuck in the 'cold' position this winter. Is there a way to manually move and fix the door to get some heat?

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gerry bissi

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  • Ford Master 4,390 Answers
  • Posted on Dec 26, 2009
gerry bissi
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Control System Inputs
Climate Control Assembly
The climate control assembly has three control systems:

  • The A/C heater function selector switch combines a vacuum selector valve for direct control of the vacuum control motors and electrical input to the instrument cluster module.
  • The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob (18519) from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain.
  • The blower motor switch controls the blower motor speed through a series of resistors and a relay.
Control System Outputs
Blower Motor Switch Resistor
The heater blower motor switch resistor has the following features:
  • The assembly is located on the passenger side of the plenum assembly behind the glove compartment (06010).
  • Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds.
  • Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed.
  • An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds except HI.
  • The thermal limiter cannot be reset.

A/C Electric Blend Door Actuator
The A/C electric blend door actuator is located on the plenum assembly.
  • Its function is to move the air temperature blend door on command from the control assembly.
  • The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door.
----------------------------------------------------------------------------------------------

  • gerry bissi Dec 26, 2009


    IT COULD BE HEATER CONTROL TEMP CONTROL OR THE BLEND DOOR ACTUATOR.

    Actuator

    Removal


        Remove the audio unit. For additional information, refer to Section 415-01 . YOU WILL NEED A SPECIAL TOOL TO REMOVE RADIO. 2 U SHPAED PINS. ABOUT $5 AT AUTO STORES.


        Remove the LH instrument panel insulator. For additional information, refer to Section 501-12 .


        Remove the electronic actuator.

            Disconnect the connector.


            Remove the screws.


            Pull down to release the actuator shaft and remove the actuator.





    Installation


        To install, reverse the removal procedure

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Johnny Brown

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  • Ford Master 5,763 Answers
  • Posted on Dec 26, 2009
Johnny    Brown
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You have to replace the blend (heat/cold) door motor, you can try to remove motor and turn door and try to jam something in door handle slot ,that the part that the motor turns,hope this helps.

  • krazy556 Aug 31, 2011

    If you take the motor off you can open it and take out the lever that turns the heat/cold door thats what I did and just left it on there until I got a replacement motor and manualy changed the heat to cold or hot. hope this helps.

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In all modern cars there is a tiny DC electric motor driven gear drive that moves a plastic door that blends heated and cooled air from the AC and the heater core, this is called (interestedly enough) the air temperature control blend door actuator. The motor that moves this door fails because the door starts sticking from warping, most common complaint is no heat but it can be no AC as well. To replace these parts (blend door and blend door actuator) you must remove the entire dash from the car. Always have this problem confirmed by a dealer or qualified repair shop as it is a very expensive repair.

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Section 12-02: Heating and Defrosting 1998 Windstar Workshop Manual
REMOVAL AND INSTALLATION Actuator Motors, Electric Temperature Blend Door
Removal
  1. Remove cassette storage box or center shelf unit, if equipped.
  1. Remove instrument panel ash receptacle (04810) by depressing service lever.
  1. Disconnect electrical harness connector from electric blend door actuator.


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  1. Remove three retaining screws.


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  1. Carefully pull electric blend door actuator outward and off A/C evaporator housing (19850) assembly.
Installation
  1. Follow removal procedure in reverse order.
  1. Air temperature control door shaft is keyed. Move door to properly insert electronic actuator shaft. Make sure the shaft is completely in and properly seated.
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