I have an 03 windstar. When starting the car, there was a repetitive
clunking sound under the dash, likely a damper opening and closing. It
continued for a couple of minutes and then quit. After that, no heat. The
fan works and the selector damper still works, sending air to the dash
vents, defroster etc. No heat, however. I can still get heat from the rear
seat heater.
Is this damper vacuum operated or electric? Is there a relay that could be
causing this problem?
Denis Roy
mechanic@telusplanet.net - 26 Oct 2008 03:17 GMT
I vaguely recall a TSB for a similar concern on Freestar/Windstar.... I only
ever saw one with the concern and it fits your symptom pretty good.... You
might try getting your dealer to run an OASIS on your VIN using noise and/or
climate control concern codes. IIRC, the repair involved a new blend air
door motor....
>I have an 03 windstar. When starting the car, there was a repetitive
>clunking sound under the dash, likely a damper opening and closing. It
[quoted text clipped - 6 lines]
>
> Denis Roy
Kruse - 28 Oct 2008 00:33 GMT
> I have an 03 windstar. When starting the car, there was a repetitive
> clunking sound under the dash, likely a damper opening and closing. It
> continued for a couple of minutes and then quit. After that, no heat. The
> fan works and the selector damper still works, sending air to the dash
> vents, defroster etc. No heat, however. I can still get heat from the rear
> seat heater.
Go to google and type in: "ford blend door fixes". View a couple of
these web pages and you will know what you are in for.
Not sure how mechanically inclined you are, but you could save some
money by doing this yourself.
Denis Roy - 29 Oct 2008 05:20 GMT
Thanks for the reply. I took it to the local mechanic who found it to be
the blend door motor. 1 1/2 hours labour plus $90 for a new part from ford.
When I see how much had to be taken apart from the dash I am glad I got
someone else to do it. Money well spent.

Signature
Denis Roy
nutimikguy@gmail.com
>> I have an 03 windstar. When starting the car, there was a repetitive
>> clunking sound under the dash, likely a damper opening and closing. It
[quoted text clipped - 10 lines]
> Not sure how mechanically inclined you are, but you could save some
> money by doing this yourself.
aarcuda69062 - 29 Oct 2008 21:22 GMT
> Thanks for the reply. I took it to the local mechanic who found it to be
> the blend door motor. 1 1/2 hours labour plus $90 for a new part from ford.
> When I see how much had to be taken apart from the dash I am glad I got
> someone else to do it. Money well spent.
You got hosed.
The temperature blend door actuator is easily accessed by removing the
radio which, with the proper tools, takes about 20 seconds.
Warranty labor time; .3
Customer pay labor time; .5
Caesar Romano - 29 Oct 2008 23:05 GMT
>> Thanks for the reply. I took it to the local mechanic who found it to be
>> the blend door motor. 1 1/2 hours labour plus $90 for a new part from ford.
[quoted text clipped - 5 lines]
>The temperature blend door actuator is easily accessed by removing the
>radio which, with the proper tools, takes about 20 seconds.
What are the proper tools?
Where do you get them?
How do you use them?
How much do they cost?
Sometimes paying for what you don't know is worth the price.
Starscream - 30 Oct 2008 01:40 GMT
>>> Thanks for the reply. I took it to the local mechanic who found it to be
>>> the blend door motor. 1 1/2 hours labour plus $90 for a new part from ford.
[quoted text clipped - 11 lines]
>
> Sometimes paying for what you don't know is worth the price.
two u-shaped pieces of coathanger wire will allow to remove the radio
Like almost any OEM car radio
aarcuda69062 - 30 Oct 2008 02:45 GMT
> >> Thanks for the reply. I took it to the local mechanic who found it to be
> >> the blend door motor. 1 1/2 hours labour plus $90 for a new part from
[quoted text clipped - 8 lines]
>
> What are the proper tools?
Ford radio removal tools.
http://www.nextag.com/ford-radio-removal-tool/search-html
> Where do you get them?
Any Walmart, FLAPS, tool truck, stereo wholesaler, etc.
> How do you use them?
You poke them into the holes along each side of the radio, then pull the
radio out.
> How much do they cost?
About five bucks.
> Sometimes paying for what you don't know is worth the price.
Caesar Romano - 30 Oct 2008 14:19 GMT
>> What are the proper tools?
>
>Ford radio removal tools.
>http://www.nextag.com/ford-radio-removal-tool/search-html
Thanks for the informative post!!!