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View Full Version : Addition to Idiot's Guide to Blend Door Actuator Replacement


BigCars4Ever
10-21-2011, 05:00 PM
I recently did the blend door actuator replacement and have a few additions for the thread.
First, I needed to remove these bolts too to get the dash to move forward enough.
http://www.mercurymarauder.net/gallery/data/642/medium/Photo0127.jpg

Then I made a custom tool to help get the job done while retaining my sanity! The tool was made by grinding a cheap 8mm chinese socket (1/4" drive) to fit a 7/16" open gear wrench. This yields a tool that clears the top of the actuator when engaged on the head of the bolt but still short enough to easily fit under the cowl to get to the forward screw!
http://www.mercurymarauder.net/gallery/data/642/medium/Photo0129.jpg
http://www.mercurymarauder.net/gallery/data/642/medium/Photo0128.jpg
The tape helps hold the new socket in place so it doesn't fall out of the gear wrench.
http://www.mercurymarauder.net/gallery/data/642/medium/Photo0130.jpg
I ground the socket with a bench grinder. Go slow and test fit often. Remeber hex means six!
http://www.mercurymarauder.net/gallery/data/642/medium/Photo0131.jpg
Hope this helps!
88LTDCV351
10-21-2011, 05:10 PM
Thanks. My actuator has been showing signs of going out several times now but so far has luckily started to work again. I'm dreading having to tear in there and attempt this repair.
capt512
10-27-2011, 07:57 PM
My actuator just stopped working as it should today, won't get off hot now. Getting 024 & 025 (both blend door codes?). You should make that little ground socket for sale, i'd buy one! lol
88LTDCV351
10-27-2011, 07:59 PM
Well, with colder weather coming up, maybe you can get through the winter with just the heater.
71cyclone
10-28-2011, 03:49 AM
Man that "SNAP ON TOOL LOOKS NICE"
jstevens
10-28-2011, 04:22 AM
Might want to patent that little baby.
BigCars4Ever
10-28-2011, 05:49 PM
I keep a drawer of cheap tools for just this kind of thing. I have wrenches cut ground and welded to fit where needed.
capt512
10-28-2011, 06:45 PM
Well no luck on extending the life of my actuator, cleared the codes, etc and now it is stuck on cold. So ordered another one, which should be at my local oreilly tommorow morning. Looks like i'll be attempting the job tommorow, gonna try and make a tool like yours tonight...
Blk Mamba
10-29-2011, 09:09 AM
Mine went out last week, so I'm in the market for someone to do it, I heard of a local guy that will do it for $250 plus parts, so I'm going to go talk to him.
BigCars4Ever
08-31-2014, 06:59 AM
Haven't seen this in person but this may be similar in size of what I made
http://www.harborfreight.com/combo-go-thru-socket-set-sae-metric-21-pc-67974.html
Ken
08-31-2014, 07:26 AM
Bought a set, just in case...
fastblackmerc
08-31-2014, 08:26 PM
Mine went out last week, so I'm in the market for someone to do it, I heard of a local guy that will do it for $250 plus parts, so I'm going to go talk to him.

I get $300.00 + part ($75.00 genuine Ford part). I do it the correct way.... no short cuts.
Vostok
09-01-2014, 01:11 AM
This set is your friend.

Just got it recently. Comes in handy a lot.

https://s3.amazonaws.com/bonanzleimages/afu/images/1159/2662/71/__12.jpg