Ford F150: Heater Works On Defrost & Vent BUT NOT On Floor Or Max A/C

In this video I have a look at an old school vacuum HVAC system on a 2003 Ford F-150. This one the customer originally complained about "No A/C." Come to find out, it is more of a problem with the mode operation than lack of A/C. -Enjoy
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Due to factors beyond the control of South Main Auto Repair, it cannot guarantee against unauthorized modifications of this information, or improper use of this information. South Main Auto Repair assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. South Main Auto Repair recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video. Due to factors beyond the control of South Main Auto Repair, no information contained in this video shall create any express or implied warranty or guarantee of any particular result. Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not South Main Auto Repair

[@arduinoversusevil2025]

Is this the place giving away used impacts?

[@SouthMainAuto]

Yes sir. Any chance we could talk? I have a proposition you may be interested in....

[@RJ_Taylor]

I like where this is going.

[@dannyyo7948]

used impact vajeos are awesome!!

[@SouthMainAuto]

I'd like to send my 1/2" HF Earthquake to AvE I bought to torture test for one year in a real shop environment. Used everyday for one year (still used today.) She still has some chooch left in in it and has taken off thousands of wheel nuts, been dropped, banged, beat, abused, thrown in the parts washer, covered with all types of shmoo and keeps on truckin'. However compared to my new one it seems to be loosin' a little top end power. Might make for a good BOLTR Vid being he did the original tear down on a new one...

[@RJ_Taylor]

We’d love to see a BOLTR on that thing! As good as it’s been, would be interesting to see the improvements it has as compared to the early Earthquakes. It says a lot about a tool that can survive as a daily driver at SMA.

[@nickstarks22]

Eric, pull the controller apart and replace the oring inside each of the 4 solenoids. It sounds difficult but only takes 10 minutes and is rather easy. I've done it on three different vehicles and it had worked perfectly every time, and it costs about a dollar!

[@omaralamy4697]

Nick Starks just a note, some models have non removable solenoids. I believe up to 02 they used non removable ones that are riveted in place.

[@crabby125]

My 06 crown vic had the same problem a few years ago, did the oring fix and within minutes it was working. they use 007 style orings easy fix.

[@jhonditch4269]

@@omaralamy4697 when were rivets a problem drill those frog sounds out rivet rivet rivet

[@nickstarks22]

Omar Alamy, I did this fix on my 02 King Ranch and was able to disassemble the solenoids in place and replace the orings. Just be sure not to bend the metal clips too far or you're SOL and will have to replace the whole unit.

[@michaelcarlson6069]

$1 in parts, but $100 in mechanic time.

[@Shockedbywater]

Eric, to you this stuff might seem like just another day but many of us find it very interesting . So thanks for taking the time to make the videos even though it really adds to the time it takes.

[@aldonco]

Eric you really go above and beyond for your customers. I would not do that I would tell a customer here is your options and that's it. Your time is also worth money that you could be fixing other cars stead of looking for parts. You're a good man.

[@mohammedmuthana5828]

Thank you for every cool repair video you do I appreciate the extra effort you do when you film while repairing Thank you from the bottom of my heart Mr Eric O.

[@w829l5]

Man, you're a great dude going out of your way to get parts for these cars/trucks that you work on, and for as cheap as possible.

[@kevinwood3883]

Guy, I really like how you actually test for functioning before you make your conclusions. Old School Mechanics! Not tought in classes anymore. (40+ year master tech here, forced into retirement)

[@joshthomas5091]

I’m getting a good education watching all of your videos.

[@rsage_]

A day at the pick-n-pull is a happy day. Just you, your tools in a wheel barrow, and good times to be had... just don't forget that one tool that you think you brought but don't fully remember... for me it's either the wire cutters or the security bit set.

[@mikechiodetti4482]

Nice Diagnostics! I saw your article in Dec 2018 Motor Age. It was about the 2007 Honda you changed the cam gear and timing belt. You did some testing with the Pico Scope to show where the problem was located. The "bad" gear looked and tested (with your digital calipers) good, but going with your gut instinct, it worked! GREAT ARTICLE. Didn't know they used the picture of you holding the gear at the beginning of the article also as "Figure 6!" Took a little looking, then low and behold there was the answer. Like you, I didn't see any thing bad with the Honda's cam gear, but you made the correct call. GOOD CALL! This video is cool. I had to to do one of these with one of our vehicles at work, PRAYED it would be the controller or the vacuum line, wound up being a bad diaphram . RATS! Replaced part, all's well with that vehicle.

[@ekimnnim3508]

Eric, I have a 2000 Buick LeSabre that was giving me heating issues in the winter. It would heat fine for about 30 miles and then turn cold, no matter if I had it on auto or manual. Watching your channel helped me with what was happening. I forget what video I watched that gave me a clue, but I think you mentioned something about the outside air sensor working in tandem with the computer to control the cabin temps. It just so happens that the sensor failed about two years ago and was reporting that it was 140 degrees outside all the time. I summarized that the computer was overriding the choice the "IDIOT" behind the wheel had selected to heat the cabin while it was being told that outside air is 140 degrees. Replaced the sensor and everything is working as it should. I hate working on automobiles, but love watching your channel keep up the good work.

[@scottxp800]

Been out of the Dealership scene for quite a while but I believe that connector would be for the 4 wheel drive selector switch. I assume the truck is 2 wheel drive. Worked beside a lot of techs over the years and you are a very competent automotive technician. Thanks for the videos, I enjoy them.

[@factsdontcareaboutyourfeel7568]

You are always trying to save the customer. That is NOT the Ford way. :D

[@buckhorncortez]

Or the GM way...or the Chrysler way and especially, not the Mercedes way...or Volvo, or...

[@mikeholt3545]

I know I can't believe he doesn't need to pull the transmission out to work on that controller!

[@JoesAutoElectric]

Nicely done Eric. I had an explorer recently with he same complaint of not switching. My customer got lucky, the main vacuum source was unplugged under the hood. Those controllers seem to fail a lot. The o-ring inside is a weak link. Good job my friend.

[@johnaclark1]

Sweet!! Love the junk yard runs! I could spend my days at the junk yard and be happy...wait, I did that 30 years ago. Well, it was fun then and is still fun now.

[@sprocket226]

Wow Eric you're up early! I'll have to catch this when I get home from work. (Broadcasted on the big screen!)

[@akawireguy1197]

I completely rebuilt the control on my old '85 Ford van. It is pure mechanical/vacuum. The southern California heat just destroyed parts of the plastic chassis. Even cable mounts were destroyed and had to be re-designed and made functional again. Now several years later it is still working fine.

[@petemedina8446]

This was very interesting I'll have to remember this if I ever get a Ford or hear about someone with the same problem. Look forward to part 2.

[@777gearhead]

FANTASTIC CONTENT AS ALWAYS. EVEN FOR HOW CRAMPED THAT FOOT WELL IS, ERIC STILL GIVES US SOME ELBOW ROOM. THANKS

[@63256325N]

Fingers crossed the pick and pull has a good one. Those controllers where gold at the yard I worked at years ago in WI. Thanks for the video.

[@baxrok2.]

A trip to the pick and pull! Yeah, I'm in. Thanks Dr. O!

[@CopCat34]

Great video. I have found Ford remanufactured parts are only so so on a good day. This was an awesome video on how to check vacuum systems. I watched the video twice. Thanks again.

[@donnyo639]

I love Pick 'N Pull. I always end up getting a few "back-up" parts, just in case mine go out or fall off. Looking forward to Part II. Great video.

[@roguedoubt]

I concur with others that have commented, could potentially be fixed by replacing O-rings. I followed the KZbin video "FordTechMakuloco Ford HVAC System Stuck" and repaired the controller on a 2009 Grand Marquis, and it's still working after a year. $1 fix vs. $500+, assuming it's just a vacuum leak at the solenoid O-rings and not another issue.

[@spelunkerd]

Spending most of every day doing electrical repair, it is interesting to diagnose a vacuum driven system. Even so, fundamentals are the same! Tubing can have holes (short to ground), or get kinked or plugged (open). I wanna see you do a vacuum drop test, ha ha. By the way, those tubing connectors look a lot like the connectors used for garden irrigation sprinkler systems. Lots cheaper at the gardening section of the hardware store compared to automotive parts stores, and I know they work for windshield washer tubing connectors, too.

[@tedchristman7618]

Drip system is good idea.

[@stephenmctaggart8400]

Thanks Eric. Good to see you working with air for a change. Love the channel.

[@jhonditch4269]

Thanks be to GOD a found a local mechanic almost as good as you. btw you're great!

[@SQLRYAN]

Another "Test, don't guess" video. Really appreciate you making these videos. 5 C-notes for HVAC head unit? Really? Wow.

[@jeffryblackmon4846]

Way to go, Eric O!

[@buckzilla1466]

Great diagnosis of the system on that 04 ford Can't wait for the field trip to pick and pull

[@klwthe3rd]

Nice to see some Ford's making it into the SMA shop. Can't over represent the Chevrolets! Never did like the Ford chimes as they are irritating as hell. Great video.

[@CSX4772]

Newer ford chimes are not as annoying. But it still gets your attention

[@gilron9585]

Thanks, I learned about vacuum here. Didn't know much about it :) would love to hear more about the actuators

[@Paul1958R]

Eric, As always a great video and diagnosis. The minute I started watch I recalled that you had a similar situation a few years ago on a late model Crown Vic/Grand Marq and that my recollection was that you disassembled it and replaced the internal o-ring seals. If you do go salvage yard route please take us along. I see lots of those units on ebay for $100-$150. SMA#1 God bless Paul

[@gearheadautomotivel.l.c.5476]

Had a similar issue on my Dodge Dakota a few months back except it was that it would only blow out of the defrost. Suppose I should clarify by saying that the problem has been occurring for years, I just finally fixed it a few months back. (A mechanic with a broken vehicle? Imagine that.) Also wound up scoring one from the Pick-n-Pull and it works great. I will hold a good thought that the automotive gods will be smiling upon you too. 😀

[@slowride55]

It does that warm up and freeze crap in NY too? Had a blizzard in November, 50 degrees in December, and another blizzard is coming this weekend here in IL.

[@CubasAutomotive]

I was expecting lightning to strike just after counting the mounting clips.... lol Took me back to Sesame St. and The Count. Bahahaha ☇☇ Love these old systems! So easy to diagnose, even if no diagram handy. This video is invaluable to the DIYer though. Ohhh... of course it's raining when you gotta go to the yard and more than likely a swampy mess otherwise! Lol Something like this, I'd normally charge labor twice, because it's essentially what you're doing, plus wear & tear and fuel used. You're lucky that new yard popped up down the street, making that more convenient! Have a great day Eric!

[@johnferguson7235]

This customer deserves special care because he didn't wait until July to come in for air conditioning repairs.

[@greasemonkey5216]

Just finished a rear axle bearing 05 Saabaru thanks to your vid not to bad Thanks Jim

[@stanisci59]

I have a 2013 Toyota Camry. Not even a Ford just like you’re videos a lot keep it up. They’re smooth. Lol👍🏻

[@coopersilberling6883]

We love a good ole 3am post

[@Reaper1947]

Thanks to all who contributed here today for the cheap O-ring fix, much appreciated. TheReaper!

[@codo7]

Waiting on part 2. Anticipating the pick n pull.

[@MrsSunshine75]

I have the earthquake cordless 1/2” impact & 3/8” ratchet because Eric O. uses them, just sayin.. & so far after a couple months I’m very impressed, On another note I’ve had a earthquake 1” air powered extended anvil impact that’s been taking off big truck wheels for prob 9 yrs with no problem!!

[@IBenZik]

"Why" because you said so! Great video.

[@HUBBABUBBADOOPYDOOP]

My '89 Buick uses a similar system. Same vacuum accumulator, check valve. The mode door controller is called the "Programmer" and controls the blend door and vacuum motors. Many of those units are easily repairable. The rubber seals dry out. Squirt a couple shots of silicone in it, freshen up the seals. Exercise it with your mighty vac and Power Probe. Good luck at the P&P.

[@throttlebottle5906]

fish tank air valves/manifold = solved for cheap ;) well if you don't mind the "custom hackery look", then again my 1992 has leaking valving, if I use it more the seals recover, but it sits a lot.....

[@luisolivero423]

loving nick starks suggestion

[@TheVintageEngineer]

Eric, unless I missed it, You need to address testing the harness when there is more than one output. You have to block all but the port you are testing otherwise the open ports will bleed off the vacuum of the whole circuit. An open on a vacuum line is like a short to ground and brings the vacuum/voltage down to zero for all components attached to the same node. I’ve seen heater control valves leak and bring down the whole max a/c system and divert to defrost.

[@throttlebottle5906]

even with 2 ports open, the gauge should move and read something, probably not beyond 2 to 5" vacuum. it most always did/does for me. just take and jam your finger over the other hose ports. should have heard hissing/had some gauge movement still regardless, unless he had wrong half of harness (to actuators, vs. controls)

[@tommyj19751]

I have several pull and pay yards near me. I love them all. Good luck.

[@AntonioClaudioMichael]

Great video Eric O

[@draxxes1]

The extra wire on the panel is an on/off passenger airbag switch. I have it on my 2002 f-150.

[@envisionelectronics]

I can repair these. There are O-rings that leak in the module. Replace with silicone versions and it’s good to go.

[@thefunkilledu]

How hard are they to take apart, really?

[@InternetDude]

I have an 03 F150 this was the first thing I fixed on my truck when I got it. You just need to replace a few O-rings, there are videos here on KZbin on how to do that. Could have had the whole job done in under an hour. Too many uneducated people just replace the HVAC head unit which is a complete waste of time and money.

[@2secondslater]

Love your process of deduction!

[@TylersNeighborhoodGarage]

I did the o-rings on the riveted unit in my '02. I can't imagine why that all the online tutorials made sure to use the non-riveted version as an exemplar....

[@warderkeeju]

Lower left corner wire harness behind the dash panel is for the 4wd knob.

[@Mr92cadi]

I remember having that kind of set up in my 92 Seville. So much potential for failure

[@adamtrombino106]

Yeah, I watched this vid just to see where you'd be sourcing the part from. I've heard you can replace the internal o rings, but have not been able to source them. Ford doesn't offer a rebuild kit, and hence no p/n. So to all you guys and gals that say they can repair them, give a shout out on where you're getting your parts from! We thank you!

[@johnaclark1]

According to FordTechMakuLoco: @t

[@johnaclark1]

According to FordTechMakuLoco: @t

[@opl500]

Happy January. Are you shoveling snow yet?

[@717Lucero]

Hell yeah I like when you take us to go to the pick & pulls or junkyard

[@throttlebottle5906]

use a tee fitting, then you can have the gauge reading while the vacuum actuator is connected, way easier to tell if they're leaking or a linkage/damper is busted/stuck, unless you can hear the hissing. but that's kind of hard with small lines and big pots buried up in the dash

[@kevinwoodcock7578]

The trouble you go through for your customers is plain flat out amazing.

[@gregmenso1815]

Poop and laughter best substitution ever. Gotta keep it clean Eric.

[@chadboutwell4217]

Just received my SMA swag in the mail!

[@alexpuls8219]

I have the exact same truck and I was wondering if maybe the floor vent didn't work or if it just really sucked. Cuz my feet always get cold in the winter! I'll check and see if maybe this could be my issue.

[@sterlingstephens7093]

nice process of elimination👍

[@mysteryboyee]

That unused connection is for the electronic 4wd switch, or in this case, would be if it had 4wd

[@cobrasvt347]

Some of these control units also have a diagnostic mode built in that can be accessed for other problems. Depending on year. This particular issue most likely will not be detected by the module itself.

[@PrintEverything20005]

The mystery connecter is for an automatic 4wd knob

[@normangallant9879]

Good find

[@MustangMan1]

I have an 07 grand prix gxp and my AC went out. Compressor wouldnt turn on. A mechanic told me it was my controls so i went to the salvage yard and replaced the controls and it worked, for a couple of days and now it doesn't work again. Any idea what i should try next?

[@imnottheniceguy5258]

Hey my vents blow Heat all the time when it's on hot and it blows cold all the time when it's on cold but when I drive is costly heat coming from all the vents even the floor vents and when I cut the heat on to try to defrost the window it's a smell of like antifreeze and it fog the window what do you think it could be

[@danclack9648]

Can we get a link on where to get the napkin?

[@dandennis8465]

I have a 2003 F150 and to stop the seat belt from dinging you can push the red seat belt button and the beeps will stop.

[@kevinthomas895]

We need a video with the Snap on man. Its been quite some time since he has made an appearance.

[@fire7765]

I appreciate your videos, awesome.

[@jo6520]

Ford got cheap With the o rings inside the head units for these vacuum systems the crown vic has the same problem. It's a common well known problem.

[@buckhorncortez]

Yeah...the o-rings only lasted 15 years. How long do you figure an o-ring should last before it degrades from ozone? 50 years, 100 years?

[@picklerix6162]

I use to own a Ford Windstar. I was always working on that minivan. Ford buys the cheapest parts available so most of the time I was replacing incredibly cheap parts that had failed. The control knob for the rear A/C only worked intermittently. It turns out there was a vacuum leak in the control panel switch. That only cost me $29 at the dealer. The bellows on my intake manifold runner controls also started to leak. Those were not cheap at $150 each. The dealer wanted $800+ to replace the IMRC's. It takes about 15-20 minutes for a DIY mechanic to replace each IMRC so I am not sure why the labor was so expensive?

[@MH-ev3wr]

@@buckhorncortez O defender of all things Ford, all that direct sunlight and ozone will degrade the hell out of every O-ring. /sarcasm Seriously, though, the O-rings on the AC hoses in my '02 Outback still haven't leaked/failed yet. Nor have the O-rings on the fuel injectors, or any other O-ring on the car. My '87 911 has O-rings and other rubber seals on it that haven't failed yet, including the injectors, gas cap, vacuum hoses, HVAC hoses, and so on. Face it - Ford cheaped out on a non serviceable part either to save money or to make bank on remans. They could have spent an extra $0.10 per unit for the better O-rings that would have allowed the unit to last the lifetime of the vehicle but opted not to. Did they learn nothing from the Pinto?

[@jo6520]

@@buckhorncortez This was a problem from new turns out they new about the cheap o rings and the replacements are only 2.00 or less it could save you hundreds. some of them last 15 years some didn't

[@jo6520]

@@picklerix6162 the labor is high because they have a book that tells them how long the job should take and they charge about 90 dollars an hour! its BS.

[@wyattoneable]

That chart was invaluable for trouble shooting. Wow, expensive part. I like going to pick-and -pull however. Lets meet up there when it stops raining. :)

[@snoopdogie187]

Today is the day then, no rain, just snow now.

[@mikeholt3545]

We have u pull and pay my wife hates when I go there!

[@davescruton2829]

So when 3 lines should have vacuum, shouldn't you be blocking 2 lines while testing the 3rd? I would think the lack of seal on the other 2 would prevent you from getting a good reading.

[@jimhogan8808]

I was trying to tell him that while watching. But guess I was not load enough. I believe you are correct it will not pull vacuum when one hose is open to atmosphere. Eric o. I do love the channel, perhaps you needed more coffee?

[@zx8401ztv]

Now that sucks :) Yep every one from a scrap yard could be buggered as well. I think looking inside the unit is what i would do, see if the fault is obvious.

[@michaelcarlson6069]

I had an Explorer with nearly identical symptoms, but the root cause was a broken damper arm in the dash just left of the glove box.

[@jamescostello6529]

Give me back the three way fan switch and the two slide levers. They never broke.

[@PatrickKanatzer]

I have a 2004 Dodge Ram 3500 (Diesel) defrost and panel work, but no floor. Bad blend door?

[@CTSCAPER]

If the fake wood panel snapped in half would the video have still been published? :-)

[@eldonerc2524]

I believe I would take my mighty vac hand pump and your vacume gauge with ya an put it through a few cycles before I put money down.

[@danrasmussen4125]

I just ran into a 99 ford ranger with random blend door issue when truck was running 4x4 never locked in turned out that the issue was a vacuum line to the pasanger side lockout

[@stanpatterson5033]

Well, I love a field trip as much as the next person does, but there's a lot of comments saying this is both an easy, and a cheap fix (and sounds like it's a permanent one if you use silicone O-rings instead of cheapies). If it were my call, I'd go ahead with the field trip, get a few replacement units if they're super cheap, and keep them with the intent of using one as a lab-rat to experiment on with replacing the leaky O-rings. These controllers don't look all that huge, so you could put a few of them in a shoe box and keep 'em in stock in the building, that way if you ever got another Ford/Merc/Lincoln that needed one, you'd have one on hand. I don't know if color is an issue, or if they're all the same black color, but sounds like something that's easy to do.

[@laurianopaniagua3825]

Hi Eric. I have a f150 2006. I have a problem with my switches if I turn my seat heater on it turns my dashboard on instead, if I put the air on my feet it turns the air on on a different setting. What do you think is the problem?

[@stephenrankin2078]

Good morning Eric

[@aaa000777]

Does United Radio repair these modules? Might be worth a call.

[@brentnearhood8874]

Eric, replace the o-rings in the controller!

[@fascistpedant758]

When checking vacuum on yellow and blue at 7:45, maybe you should block one while checking the other one. I imagine the open line would be a major vacuum leak. Why is he complaining about no a/c in January anyway?

[@williamsquires3070]

anti chuckle - Maybe he came up North from Texas? Down here, even winter can sometimes be unseasonably warm!

[@Archer2929]

I caught the same thing but figured I would read the comments before posting.

[@122ffsdd]

Wouldn't you fix the AC before it gets warm...

[@fascistpedant758]

I was just pointing out the irony of fixing the a/c at a time when everyone up here is trying to stay warm.Regardless of whether or not the a/c works, you still need proper ventilation in the car. Just for the heater to function properly.

[@autotech2143]

William I was about to say the other day we were close to 70. I'm in North TX. I was hoping to get some ice this winter. I guess we still got till the end of February.

[@Vfh........y]

This is the exact reason I'll be keeping my 05 V6 Power Toyota Tundra. It has an 8-foot bed and can actually be used for something. And has 245 horsepower with a ton of torque. Ford and GM are getting it all wrong and now they're getting called out on it at the dealership level. It won't be long and they'll be Chinese Mexican and everybody else is brands of trucks in the United States if they can't get their stuff together.

[@buckhorncortez]

So the "exact reason" is leaking O-rings in an HVAC controller? Wow...how did you settle on that as the "exact reason"? Exactly what are Ford and GM "getting all wrong"? Parts on a 15 year old vehicle need to be replaced? So, Toyotas NEVER need parts replaced? Really? Interesting since a friend couldn't get an oxygen sensor for an 8 year old Corolla and ended up having to buy a new car to solve the problem so he had a vehicle that would pass emissions testing. Every vehicle needs parts replaced as they get older - even Toyotas.

[@MultiArrie]

@@buckhorncortez strange, after 8 years in the EU all vitalparts must be avillable at least 10 years after production end. Mercedes Benz stock almost all parts 25 years after production ends.

[@RandyTWA]

Got my muck boots and rain jacket, let’s go pick some parts. I’ll bring the coffee.

[@aleblanc3547]

Oh good, finally Ford is in good company. My 1500 GMC loves to go, "Now you're hot now you're not." ;>)

[@Blackford86]

Yo Eric you should got a little Pom-Pom and let the air blow on it😂😂

[@robopwner]

I have a similar issue except mine changes from dash/all vents to defrost almost along with engine speed and vehicle speed.

[@GTP427cobra]

My truck is a 2003 F 150 Lariat when i put it on defrost it blows out the dash vents everything else works fine

[@micheller8014]

Can you test the used one by mouth vacuum before purchase , or does it need power also?

[@mtnman6278]

Use a vacuum pump.

[@GregoryBirulkin]

Eric, listen to Nick Starks a couple rows down!

[@tgriffin6938]

Did you end up replacing the o-rings or going to the junkyard and buying another controller?