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RJ
RJ, Ford Technician
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Experience:  Ford senior master and ase master certified 19years Ford dealership experience
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How do you replace front blend door on 2000 expedition?

Customer Question

how do you replace front blend door on 2000 expedition?
Submitted: 5 years ago.
Category: Ford
Expert:  RJ replied 5 years ago.
Are you asking for specific step by step instruction?
Customer: replied 5 years ago.
Yes, I am sure it's the problem. Have seen all kinds of conflicting info on how to perform the job. Understand it's quite the task. No good one source on how to do it though. I get hot air blowing out and can hear the actuator clicking like it wants to move the door but the shaft must be broke.
Expert:  RJ replied 5 years ago.
Its quite the task, I will send you the info give me a few minutes.
Expert:  RJ replied 5 years ago.
<strong>Here is the first portion:<br /><!--<pre>--> <table border="0" width="95%"><tbody><tr><td>SECTION 412-01: Air Distribution and Filtering</td><td align="right">2000 Expedition/Navigator Workshop Manual</td></tr><tr><td>REMOVAL AND INSTALLATION</td><td align="right"><a href="javascript:load_tag();">Procedure revision date: 06/17/1999</a></td></tr></tbody></table><hr /><h4>Plenum Chamber</h4><br /><table border="1" cellspacing="0" cellpadding="3" width="50%"><caption>Material</caption><tbody><tr valign="top"><th>Item</th><th>Specification</th></tr><tr valign="top"><td>MERPOL®<br /></td><td align="center">ESE-M99B144-B</td></tr><tr valign="top"><td>PAG Refrigerant Compressor Oil (R-134a Systems)<br />F7AZ-19589-DA (Motorcraft YN-12-C)</td><td align="center">WSH-M1C231-B</td></tr></tbody></table><p><strong>Removal</strong></p><ol><li>Disconnect the battery ground cable. For additional information, refer to Section 414-01.</li></ol><ol><li>Recover the refrigerant. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?left side=/pubs/content/~WSYJ/~MUS~LEN/23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>.</li></ol><ol><li>Drain the radiator. For additional information, refer to <a href="http://www.fordtechservice.de alerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/~WSYJ/~MUS~LEN/23/SYJS330L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/23/SYJS330R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 303-03</a>.</li></ol><ol><li>Remove the instrument panel. For additional information, refer to Section 501-12.</li></ol><ol><li>If equipped with 5.4L 4V engine, remove the junction block splash shield.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1622/AM1692A.gif" border="1" alt="" width="269" height="175" /></ul><ol><li>If equipped with 5.4L 4V engine, disconnect the cable ends.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1580/AM1630A.gif" border="1" alt="" width="269" height="174" /></ul><ol><li>If equipped with 5.4L 4V engine, remove the junction block bracket. <ol><li>Disengage the connector.</li></ol><ol><li>Remove the screws.</li></ol><ol><li>Remove the junction block bracket.</li></ol></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1586/AM1631A.gif" border="1" alt="" width="269" height="175" /></ul><ol><li>Disconnect the heater hose couplings. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?left side=/pubs/content/~WSYJ/~MUS~LEN/23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1642/GL0469A.gif" border="1" alt="" width="269" height="174" /></ul><ol><li>Disconnect the refrigerant line spring lock couplings from the A/C evaporator core (19860). For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?left side=/pubs/content/~WSYJ/~MUS~LEN/23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>. <ul><li>Discard the O-ring seals.</li></ul></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1637/GL0595A.gif" border="1" alt="" width="269" height="169" /></ul><ol><li>Remove the plenum chamber nuts (engine side).</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1644/GL0587A.gif" border="1" alt="" width="269" height="173" /></ul><ol><li>Disconnect the A/C vacuum hose from the A/C vacuum check valve.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1634/GL0486A.gif" border="1" alt="" width="269" height="169" /></ul><ol><li>Remove the plenum chamber nuts (interior).</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1650/GL0588A.gif" border="1" alt="" width="269" height="173" /></ul><ol><li>Remove the plenum chamber.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1656/GL0589A.gif" border="1" alt="" width="269" height="169" /></ul><p><strong>Installation</strong></p><ol><li>To install, reverse the removal procedure. <ul><li>Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed.</li></ul><ul><li>Install new O-rings lubricated in clean PAG oil.</li></ul></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1866/A0036173.gif" border="1" alt="" width="269" height="175" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1858/A0036172.gif" border="1" alt="" width="269" height="174" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1642/AM1677A.gif" border="1" alt="" width="269" height="174" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1636/AM1676A.gif" border="1" alt="" width="269" height="172" /></ul><br /><hr /><p> <img border="0" alt="" width="1" height="1" /> </p><!--SOME VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT A FLUTTER TYPE NOISE FROM THE AIR BOX/INTAKE AREA ON DECELERATION. THIS NOISE TYPICALLY OCCURS WHEN DECELERATING AFTER HEAVY ACCELERATION. THE NOISE IS A NORMAL CHARACTERISTIC OF THIS ENGINE AND HAS NO IMPACT ON ENGINE OR TURBOCHARGER DURABILITY. NO REPAIR ATTEMPT SHOULD BE MADE FOR THIS CONDITION.--><!--</pre>--></strong>
Expert:  RJ replied 5 years ago.
<strong>Here is the first portion:<br /><!--<pre>--> <table border="0" width="95%"><tbody><tr><td>SECTION 412-01: Air Distribution and Filtering</td><td align="right">2000 Expedition/Navigator Workshop Manual</td></tr><tr><td>REMOVAL AND INSTALLATION</td><td align="right"><a href="javascript:load_tag();">Procedure revision date: 06/17/1999</a></td></tr></tbody></table><hr /><h4>Plenum Chamber</h4><br /><table border="1" cellspacing="0" cellpadding="3" width="50%"><caption>Material</caption><tbody><tr valign="top"><th>Item</th><th>Specification</th></tr><tr valign="top"><td>MERPOL®<br /></td><td align="center">ESE-M99B144-B</td></tr><tr valign="top"><td>PAG Refrigerant Compressor Oil (R-134a Systems)<br />F7AZ-19589-DA (Motorcraft YN-12-C)</td><td align="center">WSH-M1C231-B</td></tr></tbody></table><p><strong>Removal</strong></p><ol><li>Disconnect the battery ground cable. For additional information, refer to Section 414-01.</li></ol><ol><li>Recover the refrigerant. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/~WSYJ/~MUS~LEN/ 23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>.</li></ol><ol><li>Drain the radiator. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/ren derers/reload_frames.asp?leftside=/pubs/content/~WSYJ/~MUS~LEN/23/SYJS330L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/23/SYJS330R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 303-03</a>.</li></ol><ol><li>Remove the instrument panel. For additional information, refer to Section 501-12.</li></ol><ol><li>If equipped with 5.4L 4V engine, remove the junction block splash shield.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1622/AM1692A.gif" border="1" alt="" width="269" height="175" /></ul><ol><li>If equipped with 5.4L 4V engine, disconnect the cable ends.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1580/AM1630A.gif" border="1" alt="" width="269" height="174" /></ul><ol><li>If equipped with 5.4L 4V engine, remove the junction block bracket. <ol><li>Disengage the connector.</li></ol><ol><li>Remove the screws.</li></ol><ol><li>Remove the junction block bracket.</li></ol></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1586/AM1631A.gif" border="1" alt="" width="269" height="175" /></ul><ol><li>Disconnect the heater hose couplings. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/~WSYJ/~MUS~LEN/ 23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1642/GL0469A.gif" border="1" alt="" width="269" height="174" /></ul><ol><li>Disconnect the refrigerant line spring lock couplings from the A/C evaporator core (19860). For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/~WSYJ/~MUS~LEN/ 23/SYJSC00L.HTM&rightside=/pubs/content/~WSYJ/~MUS~LEN/24/SYJSC00R.HTM&contenttype=WORKSHOP&workunit=SYJ&market=US&language=EN&viewer=IE" target="_parent">Section 412-00</a>. <ul><li>Discard the O-ring seals.</li></ul></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1637/GL0595A.gif" border="1" alt="" width="269" height="169" /></ul><ol><li>Remove the plenum chamber nuts (engine side).</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1644/GL0587A.gif" border="1" alt="" width="269" height="173" /></ul><ol><li>Disconnect the A/C vacuum hose from the A/C vacuum check valve.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1634/GL0486A.gif" border="1" alt="" width="269" height="169" /></ul><ol><li>Remove the plenum chamber nuts (interior).</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1650/GL0588A.gif" border="1" alt="" width="269" height="173" /></ul><ol><li>Remove the plenum chamber.</li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1656/GL0589A.gif" border="1" alt="" width="269" height="169" /></ul><p><strong>Installation</strong></p><ol><li>To install, reverse the removal procedure. <ul><li>Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed.</li></ul><ul><li>Install new O-rings lubricated in clean PAG oil.</li></ul></li></ol><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1866/A0036173.gif" border="1" alt="" width="269" height="175" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1858/A0036172.gif" border="1" alt="" width="269" height="174" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1642/AM1677A.gif" border="1" alt="" width="269" height="174" /></ul><ul><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/~WS-V-B/1636/AM1676A.gif" border="1" alt="" width="269" height="172" /></ul><br /><hr /><p> <img border="0" alt="" width="1" height="1" /> </p><!--SOME VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT A FLUTTER TYPE NOISE FROM THE AIR BOX/INTAKE AREA ON DECELERATION. THIS NOISE TYPICALLY OCCURS WHEN DECELERATING AFTER HEAVY ACCELERATION. THE NOISE IS A NORMAL CHARACTERISTIC OF THIS ENGINE AND HAS NO IMPACT ON ENGINE OR TURBOCHARGER DURABILITY. NO REPAIR ATTEMPT SHOULD BE MADE FOR THIS CONDITION.--><!--</pre>--></strong>
Expert:  RJ replied 5 years ago.
Here is the instrument removal: SECTION 501-12: Instrument Panel and Console 2000 Expedition/Navigator Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 08/12/2004

--------------------------------------------------------------------------------

Instrument Panel
Removal

CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

If equipped with adjustable pedal system, move the pedals to the full forward position.
If equipped, remove the front floor console. For additional information, refer to Console — Floor, Front in this section.
Remove the passenger air bag module. For additional information refer to Section 501-20B.
Position the battery junction box (BJB) power distribution box aside.
Release the mounting tabs.

Remove the bulkhead electrical connectors from inside the engine compartment.
Loosen the bolts.
Disconnect the bulkhead electrical connectors.

Remove the bulkhead electrical connector insulator.

Unclip the bulkhead electrical connectors from the dash panel.

Remove the lower instrument panel steering column cover. For additional information, refer to Instrument Panel — Steering Column Cover in this section.
Remove the valance panel.
Remove the two pin-type retainers and release the expander clip.

Remove the RH instrument panel insulator.
Disconnect the restraint control module (RCM) electrical connector.
Release the locking tab.
Disconnect the RCM electrical connector.
Release the wiring harness locators.

If equipped, disconnect the park brake release solenoid electrical connector.

Disconnect the electronic blend door actuator electrical connector.
Release the wiring harness locators.

Disconnect the climate control head vacuum harness connector.

Remove the LH and RH scuff plates.

Position the LH and RH door weatherstrip seals aside.

Remove the LH and RH A-pillar lower trim panels.

Remove the RH and LH assist handles (31406).
Remove the covers and the bolts.
Remove the assist handles.

NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook.

Remove the LH and RH windshield side garnish mouldings (03598).
If equipped, on the LH windshield garnish moulding, disconnect the cellular phone hands-free microphone electrical connector.

Disconnect the brake pedal position (BPP) switch electrical connector.
Release the wiring harness locator.

If equipped, disconnect the adjustable pedal motor harness electrical connector and release the locator.

Disconnect the LH instrument panel main wiring harness connectors and bulkhead connector.
Loosen the bolt.
Disconnect the electrical connectors and the bulkhead connector.
Remove the LH ground bolts.
Release the main wiring harness locators.

Remove the instrument panel steering column opening cover reinforcement (04502).
Remove the nuts.
Remove the instrument panel steering column opening cover reinforcement.

Disconnect the electrical connectors.

Disconnect the remaining electrical connectors on the steering column.

Disconnect the transmission range indicator from the steering column.
Remove the bolt.
Disconnect the cable.

Lower the steering column (3C529).
Remove the nuts.
Lower the steering column.

Remove the instrument panel bolts through the steering column opening.

Remove the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.

Disconnect the RH instrument panel main harness connectors.
Disconnect the instrument panel harness connectors.
Disconnect the inertia fuel shutoff switch electrical connector.
If equipped, disconnect the air suspension switch electrical connector.
Remove the RH ground bolt.
Release all the wiring harness locators from the cowl side panel.

Disconnect the blower motor electrical connector.

If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.

Disconnect the in-line antenna connector.

Remove the instrument panel bolts through the passenger side air bag module opening.

Remove the instrument panel bolt on the relay bracket.

Remove the instrument panel reinforcement bolt below the LH corner of the glove compartment.

NOTE: Position the carpet aside.

Loosen the instrument panel floor brace.
Remove the upper instrument panel floor brace bolt.
Loosen the instrument panel brace bolts and nut.

Remove the RH instrument panel cowl side nut.

Remove the LH instrument panel cowl side nut.

On Expedition, remove the instrument panel cowl top bolts.
Remove the covers.
Remove the bolts.

On Navigator, remove the instrument panel defroster grille assembly.

On Navigator, remove the instrument panel cowl top bolts.

NOTE: This step requires an assistant.

NOTE: Two bullet connectors secure the instrument panel to the bulkhead.

Remove the instrument panel.
Installation

CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

NOTE: This step requires an assistant.

Align and position the instrument panel with the clips in the sheet metal.
On Navigator, install the instrument panel cowl top bolts.

On Navigator, install the instrument panel defroster grille assembly.

On Expedition, install the instrument panel cowl top bolts.
Install the bolts.
Install the covers.

Install the LH instrument panel cowl side nut.

Install the RH instrument panel cowl side nut.

NOTE: To prevent squeaks or rattles, install and tighten the upper instrument panel floor brace bolt first, and then tighten the floor brace bolts and nut.

NOTE: Reposition the carpet after this step is performed.

Install the instrument panel floor brace.
Install the upper instrument panel floor brace bolt.
Tighten the instrument panel floor brace bolts and nut.

Install the instrument panel reinforcement bolt below the LH corner of the glove compartment.

Install the instrument panel bolt on the relay bracket.

Install the instrument panel bolts through the passenger side air bag module opening.
Install the RH bolt first.

Connect the in-line antenna connector.

If equipped, connect the EATC hose to the evaporator case.

Connect the blower motor electrical connector.

Connect the RH instrument panel main harness connectors.
Connect the instrument panel main harness connectors.
Connect the inertia fuel shutoff switch electrical connector.
If equipped, connect the air suspension switch electrical connector.
Install the RH ground bolts.
Connect all the wiring harness locators to the cowl side panel.

Install the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.

Install the instrument panel bolts through the steering column opening.

Position the steering column.
Install the steering column support nuts.

Connect the transmission range indicator to the steering column.
Connect the cable.
Install the bolt.

Connect the remaining electrical connectors on the steering column.

Connect the electrical connector.

Install the instrument panel steering column opening cover reinforcement.
Position the instrument panel steering column opening cover reinforcement.
Install the nuts.

Connect the LH instrument panel main wiring harness connectors and the bulkhead connector.
Connect the LH instrument panel main wiring harness connectors and the bulkhead connector.
Tighten the bolt.
Install the RH ground bolts.
Insert the main wiring harness locators.

If equipped, connect the adjustable pedal motor harness electrical connector and connect the locator.

Connect the BPP switch electrical connector.
Insert the wiring harness locator.

Install the LH and RH windshield side garnish mouldings.
If equipped, on the LH windshield garnish moulding connect the cellular phone hands-free microphone electrical connector.

Install the RH and LH assist handles.
Position the assist handle.
Install the bolts and the covers.

Install the LH and RH A-pillar lower trim panels.

Install the LH and RH door weatherstrip seals.

Install the LH and RH scuff plates.

Connect the climate control head vacuum harness connector.

Connect the electronic blend door actuator electrical connector.
Insert the wiring harness locators.

If equipped, connect the park brake release solenoid electrical connector.

Connect the RCM electrical connector.
Connect the RCM electrical connector.
Engage the locking tab.
Insert the wiring harness locators.

Install the valance panel.
Install the two pin-type retainers and insert the expander clip.

Install the RH instrument panel insulator.
Install the lower instrument panel steering column cover. For additional information, refer to Instrument Panel — Steering Column Cover in this section.
Clip the bulkhead electrical connectors into the dash panel.

Install the bulkhead electrical connector insulator.

Connect the bulkhead wiring harness connectors.
Connect the bulkhead wiring harness connectors.
Tighten the bolts.

Install the BJB into the mounting tabs.

Adjust the transmission range indicator. For additional information, refer to Section 307-05.
Install the passenger air bag module. For additional information refer to Section 501-20B.
If equipped, install the floor console. For additional information, refer to Console — Floor, Front in this section.


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