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Looks like I lost what I'd originally typed in. Replaced a broken blend door & the actuator last week. Customer returned today with a popping noise. I found the door fully open in the heat position, with the actuator still trying to turn it further. Just the opposite in the cold position. Door not fully closed & the actuator already stopped.
The door is still very smooth, no binding, etc. I do automotive A/C & Heating full time in my ma & pa small but very professional shop.
Am suspecting the control potentiometer, but it is smooth & the actuator responds smoothly. Tried the second actuator & still same problem. Both the replacement blend door & both actuators are "Dorman" brand.
The clicking and poppind sound is most likely the actuator is the problem they will usually click or pop when the gears re worn, otherwise the blend door is sticking or binding causing the popping sound.
The HVAC box was obviously removed & all was cleaned spotlessly.
Yes, am familiar with that. It may be that the 1st replacement actuator bit the dust. I feel relatively certain that NO problem existed when I finished the vehicle a week ago. The customer left on a trip & before returning complained about the problem.
If you need I can send test procedures.
I tried another new actuator today. Didn't bolt it in, but with the tang engaged with the door, it turns freely as usual, but the blend door stops in the fully open (heat) position & the actuator is still trying to turn it. Just the opposite true in the cols position. Actuator stops & the door is not fully closed. No problems with heat, flushed & serviced the eng coolant system on the same visit.
I am pretty certain that the just replaced blend door is fine. With a small piece of vacuum tubing inserted, I can turn the door freely with my fingers. Can feel it hit both stops with a nice little thud. Quite confident it is not binding. (8+ yrs self emp & 6 in large A/C shop prior)
I feel the new actuator is probably OK. It is not OEM, but "Dorman" replacement parts have worked well for me in the past.
I've replaced only a few control potentiometers in the past, but they are usually dead & or with dead spots & this one seems quite smooth.
I removed the cover from the actuator & realized there is not "clocking" to it, the feedback potentiometer is a part of the output shaft, thus not adjustment or chance of mfg error that I can see.
I guess I'd like to know if an experienced Ford Tech has ever had similar problems in the past. Again, unless the Dorman Door is somehow ill designed, I am quite sure that it is the correct door, installed properly with NO binding or anything obstructing it. I could simply try a replacement control potentiometer as it simply bolts to the A/C - Heater Control Head. I believe it is a YH1503, but I hate being a darn parts changer! lol
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