1999, looks like removal of the blend door is a major abortion.

Any tips?

 

whats a "blend door"?

 

I 2nd that

 

It moves to vary the air temp coming out of the vents. Changes position when you move the hot/cold dial on the dash. No real tips for you Flashman, not too difficult to remove the heat/AC box, but it is rather involved. If it has not been done yet, I'd advise replacing the heater core and AC evaporator. They will fail(sooner rather than later), and you'll have the unit out anyway to fix the blend door. And this is not a job you'll want to repeat anytime soon. HTH

 

well ill be....i learn something new everyday!

 

Why would you want to take out the blend door? If it's not working it's probably NOT the door but the door control or actuator. The early trucks just had a boden cable that mechanically moved the door but the newer trucks use an electric actuator. I think yours is the electric kind. If you look up under the dash on the pax side you'll see a little square black box with wires going to it, close to the hump in the floor. With a flash light you can see the output shaft move if you move the temp control from hot to cold. You must have the key on and a mode selected,not "off". If it moves your blend door and control are ok.

 

Like he said it's probably not the door, but the actuator. I had a 99, and had to fix that on it. It's expensive, around $150 if I remember right. Take a good look at the IC board. Mine had a little crack in it. I made a jumper accross the crack/broken track on the board, and it started working again. I also seen a good idea on this site of adding an inspection door to the AC/Heat box that I liked. If you have to remove the box, it's a bear. Good luck.

 

If the hinge is broken on the door, might look to see if you can remove a piece of the plastic in the air supply housing to get to the door. Then put the piece you cut out back in.

There was a discussion on this subject on another BB discussing this. I know on some mid 80"s Fords this was a solution to a full disassembly.