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I am having a very hard time removing the heater box to replace a broken blend door. I have removed all screws and nuts and have the dash out. But just cannot get the box out due to the rear air duct. Any advice?

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  • Cars & Trucks Master
  • 6,826 Answers

It can take a professional 5 hours to 10 hours to do the job.
If you have the dash out, then you're closer than most people who work on their broken blend door problem.

Keep on plugging.

(I don't know what car you have but most manuals do not publish this information).

Posted on Jul 21, 2010

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1 Answer

Is the blend door motor hard to replace on a 2006 crown vic


This a 5.5 hr job, it is hard to replace the dash needs to be pulled, i just did one and not fun, customer would not have heat at times and it was blend door motor , this is located at the top of the heater box and you need to pull dash back to replace and it is still a little hard getting to one of the screws in the rear of the actuator, the heater box does not need to be removed but dash pulled out.

Oct 06, 2012 | 2001 Ford Crown Victoria

1 Answer

02 dodge ram 1500 heat on passenger side of vechile only


If you are getting heat only on the pass. side then I believe the blend door has failed. Dodge has a fix and the job is not easy as almost the whole dash needs to come out in order to get to the heater box and the door. I have read that a simple flush of the heater core will cure it, But that diidn't work for me. I think because dual climate control was an option the door is set up to control the two sides of the cab. When it fails only the pass. side gets heat.

Unfortunatly you do have to remove the dash to access any of the blend door or fresh air door actuators
here is a step by step proceedure this takes aprox 5 hrs in a shop so plan on a weekend at home good luck

FLOOR - DEFROST DOOR ACTUATOR

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

Disconnect and isolate the battery negative cable.
Remove the instrument panel assembly from the vehicle.

zjlimited_318.jpg

Fig. HVAC housing, dual zone shown (single zone similar)-nut (1), passenger blend door actuator (2), nut (3), inlet baffle (4), recirc door actuator (5), recirc air door (6), driver side blend door actuator (7), HVAC housing (8), bolt (9), defroster door actuator (10), mode door actuator (11)

Remove the electrical connector from the actuator.
Remove the mounting screws from the actuator.
Remove the actuator from the HVAC housing.

INSTALLATION
Install the floor-defrost door actuator to the HVAC assembly.
Install the mounting screws and tighten to 2.2 Nm (20 in. lbs.) .
Install the actuator electrical connector.
Install the instrument panel assembly into the vehicle.
Connect the battery negative cable.

I suggest check (or replace if is necessary), the blend door it is a huge project you have to remove the dash board. There is a repair kit available either way it is a 8 hr shop time project.

Hope helps.

Dec 27, 2010 | 2002 Dodge Ram Maxi

1 Answer

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


ccl3438a.gif

  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.

Dec 17, 2010 | 1992 Mercury Grand Marquis

1 Answer

Replacing a blend door accuatior on a 2002 ford explorer


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.

Feb 01, 2010 | 2002 Ford Explorer

1 Answer

How to remove the blower motor from a 1978 ford bronco full size truck?


Deluxe Hi-Lo Heater
  1. Disconnect the battery cable, remove the carburetor air cleaner and partially drain the coolant system.
  2. Remove the heater hoses from the heater core.
  3. Remove the glove box liner and remove the register duct by pulling from the instrument panel register and releasing the clip at the plenum.
  4. Disconnect the right cowl outside air inlet vacuum hose from the outside/recirculating door vacuum motor.
  5. Remove the rear housing from under the instrument panel. Remove the outside air inlet duct from the rear housing (4 nuts and 1 bolt) and install one upper nut to retain heater housing-to-dash after rear housing is removed.
  6. Remove two screws retaining plenum-to-dash (above transmission tunnel) and two screws to heater housing and remove the plenum.
  7. Install a piece of protective tape on A-pillar inner cowl panel, at lower right corner of instrument panel.
  8. Remove the lower right instrument panel-to-A-pillar bolt to hold the panel in the rearward position.
  9. Remove the heater core (3 screws retaining 2 plates).
  10. Remove the temperature blend door (snaps off).
  11. Remove the temperature blend door arm support (2 screws) and pivot arm retainer (1 screw).
  12. Remove blower motor (2 screws) and remove blower wheel.

To install:
  1. Transfer blower to blower motor and panel assembly.
  2. Install door arm pivot retainer (1 screw) and door arm support (2 screws).
  3. Install the temperature blend door (snaps on).
  4. Install heater core.
  5. Install the plenum (4 screws).
  6. Connect blower wires.
  7. Remove heater housing upper retaining nut and install the heater outlet (4 nuts and 1 bolt). Position the air inlet duct.
  8. Connect the white vacuum hose to the outside/recirculating door vacuum motor.
  9. Reposition the instrument panel, install the retaining bolts and remove the protective tape at the A-pillar inner cowl panel, lower right corner of instrument panel.
  10. Install the right register duct assembly and install the glove box liner.
  11. Connect heater hoses to the heater core assembly.
  12. Fill cooling system, install the air cleaner and connect the battery cable to the battery.
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Jan 19, 2010 | 1981 Ford Bronco

1 Answer

How do i take the heater core out of my 81 f150


Disconnect battery ground cable. 
Disconnect cable from temperature blend door and the mounting bracket from top of heater assembly. 
Disconnect blower motor and resistor electrical connectors. 
Disconnect and plug hoses from heater core. 

Working under instrument panel, remove 2 nuts on 1980---81 models, or 3 nuts on 1982---87 models, attaching left side of heater assembly and right side of plenum to dash.

On 1980---81 models, remove screw attaching top center of heater assembly to dash. On all models, remove 2 screws attaching right side of heater assembly to dash, then lift heater assembly out of vehicle. 

Remove heater housing plate attaching screws, nut and bolt and the plate. On 1980---82 models, remove 3 heater core frame attaching screws and the frame. On all models, slide heater core and seal out of heater assembly.

Reverse procedure to install. Good Luck and hope this helps

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1 Answer

01 jeep grand cherokee heater works on driver side blows cold on passenger side


You have 2 posibilities.there are 2 motors on the heater box that run the blend doors for each side.That side motor may be bad or worst case the blend door arm that connects to the motor is broken.If it is broken the whole dash has to be removed so the heater box can be taken out to replace the blend doors.Big job,do a heater core while your there if you fix it so you dont have to do it again.

Mar 09, 2009 | 2001 Jeep Grand Cherokee

2 Answers

Blend door heater all hot


No need to do that, behind the glove box is the blend door motor, it most often breaks the shaft of the blend door, which causes a costly fix, and it will break it again. There are sites that tell you how to remove the motor, drill a small hole and put a pin in the shaft so that the motor will still turn the broken connector, I did this and my blend door is still working 5 years later. I have heard stories of people paying up to $700.00 to have the original blend door replaced, and it breaks again.

Jul 15, 2008 | 1998 Ford Explorer

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