2003-2006 Ford Expedition: Rear HVAC Temperature Blend Actuator Clicking Repair

This is the actuator needed for the repair-
2003-2004-
www.amazon.com/gp/product/B004...
2005-2006-
www.amazon.com/gp/product/B004...
This is the flex head 8mm gear wrench I used-
www.amazon.com/gp/product/B000...
In this video I should you a few tricks to replacing the rear temperature blend door actuator on these trucks without pulling the entire panel off.

[@kathleenmedi5881]

OMG! I’m a 50 year old woman in was able to (after watching this video a couple times) change the rear actuator in my 2005 expedition with NO problems. Thank you for posting this video. You saved me boatloads and gave my kids air conditioning.

[@FordTechMakuloco]

Nice!

[@Mike-gt1cs]

Kathleen Medi Good job, Mom!!

[@rmwarwick]

Great video!! Thanks for taking the time to do this. I'm replacing the rear blend door actuator on my Expedition for the FIFTH TIME tonight. That's five times in 14 years and 170k miles. This video is very helpful because I don't do it often enough to remember the details.

[@redsquirrel4923]

Well Done ! I completed the replacement in < 30 mins. I appreciate your efforts; they are not in vain !

[@michaelkilimanjaro9926]

Freaking awesome video. I put up with this stupid noise for months. Few days of research, I was able to order $45 replacement. After contemplating for 3 weeks (because my lack of confidence in mechanical common sense), I decided to do it today. I am so glad I watched this video. I followed exact steps and was able to replace the actuator in 30 minutes. That flex wrench suggestion was right on the money. If I can do it anyone should be able to do it as well.

[@BarrettTeague]

You’d be surprised at what you can fix on your own with a little common sense and a good KZbin video.

[@shaunspellman2856]

Can I borrow that flex wrench??!!

[@da12641]

Thanks to you, I'm able to replace both the rear. First time doing this and it took a little over 30 minutes. There was a local shop was going to charge $240/hr to diagnose. The amazing link is very helpful as well. Now my 2003 Lincoln is blowing cold air again.

[@michaelmartin7444]

Just finished installing 2 new actuators on my wife's 2016 Expedition, first one didn't do the trick (rear heat wouldn't blow and there was a clicking noise), then my wife found this video and watched it, bought another actuator and did the trick. Thank you for making this video, $30 is much better than $1,000.

[@brucegrunewald8423]

This is one of the best produced "car fix" videos I have seen. The lighting is good so you can actually see what is being worked on. Sound is clear. Kudos!

[@jc1556]

Used this video to replace both the temperature blend actuator and air distribution actuator for 2005 EB Expedition. Only took about 30-40 minutes and about $80 worth of parts. Spend the money on the wrench, trust me. Great video, thanks!

[@halkerkhoff2713]

Thanks for the great and informative video. I spent Sunday morning changing out this door. 45 minutes and done on my 2007 Expedition. My part number was slightly different but the process was the same. Thanks for making my repair a lot less expensive for me!

[@MiguelGonzalez-ul5fm]

I also have a 2007 Ford EXPEDITION. Do u have the part number? I want to get rid of that clicking noise

[@joetarlos]

Thanks Brian on taking your time on making video's on your repairs that your doing. I have a 2006 Expedition that I've had problems with like the HVAC actuator that I ended up changing myself after watching your helpful video's. Keep up the good work and thank you for your help and secrets on how to repair different items....

[@Kilohana67]

Thanks for this video. Loosening the C-pillar trim is actually very important in being able to get room for your hands inside the rear trim panel. I used a 2x2 by 12-14” long to wedge behind the A/c pipes and trim panel to hold it away to create just enough space. Also, I went to Amazon to buy one of those little ratcheting drivers as he suggested.

[@klatoo14]

Fixed mine today as well. While I had everything open I went a head and changed out both. Also disassembled and potentially fixed my back up camera as well.

[@LindaClements]

I originally searched for the back back way back passenger window mysteriously opened and I didnt know it until it started POURING..... searched how to close it and your video popped up first :-D PERFECT because my back A/C has been tapping LOUDLY for about a year now. I never knew why, I just never used it any more. Its great to know it can be repaired and based on what I just saw, I think I could probably do it myself. The husby wants me to get rid of the car but I am protesting because I LOVE the car. It knows me. I know it. We are one :-D Thank you for posting this !!!

[@royschwartz3502]

Thanks, helped me with the replacement. Turns out the keyed plastic shaft of the new actuator didn't want to go in. Ended up filing the edges of the shaft at the tip then it slid on. Much appreciated!

[@GrillingNetwork]

You Rock!! This video just saved me tons of money!! This noise has been bugging for some time now and if I knew it was this easy to fix, I would have done it sooner

[@adalmadera25]

Changed this part out and it started having the same issues a year later. I believe motorcraft should sell better parts. I appreciate you sharing how to replace it.

[@zr1daddy14]

We have one at the shop right now same car also and because of your vid you safe me some time thank you

[@michaelbruneau7677]

Saved me a lot of time, thanks for the easy way to remove all the plastic in my 2003 Expedition, I used a piece of molding to prop it open and it was kinda tricky especially the side actuator, the one on top for the heater was my problem, I replaced the one you suggested and did not stop the click, so I replaced the top blend door actuator and VOILA!! But your expert info helped me a million ways thanks!!

[@robertstapler9352]

Thank you for this video. It really did help me replacing the actuator on a 2007 Expedition. I do hope you gave your supervisor a treat for making sure everything went smoothly. I'm now a subscriber. Also after I changed the actuator it was still making the popping noise. I found another actuator on the front top of the rear unit that was bad too. Changed it out and everything works like it's supposed to. Thanks again.

[@lady2is2]

A quick tip I learned is, you can remove the actuator, open it up (there's a video on his page for it) and use the shaft (D shape or T shape) as a key... To either move the Air to the tempatures you like or the direction of the vents you like) this is free because you are using the old part... Until you get a new part and it stops the clicking.... Or you can use the old part to make sure you are fixing the right problem... By following the same steps... If moving the shaft manually with the key works, you are doing it right

[@johnonthecooldoe6338]

i did the blend door actuator today and use the X key after taking it apart and seeing all the gear teeth shredded. I only use roof controls so i just turned it to roof. The front ac is noticeably colder than the rear. If i take off this part and use the key does it default to a position like its spring tension or can I turn it to full blast cold and it will stay in that position?

[@johnhughes7654]

I used your technique and replaced the actuator on my 2014 Expedition. Mission accomplished without actually removing any of the trim panels. I wouldn’t say I had “plenty of room” but was able to remove and replace the screws. Mine actually had four screws (the bottom one was a bit tricky). Thanks for the great tips!

[@jamesimhoff227]

A million thanks to you! Just what I needed on my 03 Expedition. (BTW any other baseball fans think that Brian is really Joc Pederson doing work on the side?)

[@weesloco]

A jumping Hi-5 to you!!! Looks like I'm going to be able to help some friends get that clicking noise to stop. Truly appreciate you and the video.

[@townman1]

You always take time to explain why you do what you do to get the job done, Thanks again

[@myothernewname]

Just wanted to say Thank You. As a new owner of a 2000 Expedition, your videos have helped a lot. My problem is the back a/c blows ice cold, the front is crap. Not sure if the expansion valve is stopped up or what yet. Guess I will be tearing into something tomorrow. Thanks again.

[@itsinda]

Great video with awesome hacks to make it easier. 2015 Lincoln Navigator has the same setup. Know that the Navigator had 4 screws making it a little tougher. It is definitely helpful to wedge something in the side panel to widen your working room. Thank you.

[@825Daryl]

u remind me of diesel tech Ron , he was a good man , he help me out with so much on my 6.0 now i found u thanks for the videos

[@julioaleman6555]

Thank you for your video. I was able to get it done in 30 minutes. It was easy to follow.

[@Orginal_Sinner]

Thank you I appreciate you for this video. Saved me time and money

[@myriadcorp]

I just fixed my 2003 today. It was the second time the teeth broke since we purchased it back in 2003. I used your amazon links for the part and a fuel filter. I had to take the seat belts and side panels off to get access to it.

[@ronaldcorum2106]

Thanks man .This video helped me out a lot. Noise free

[@holisticcatalyst]

Very thorough teacher, and thank you for helping so many including myself to save a few dollars. I just thought of adding this, I am 6'4 big hands, I dropped the wrench, recovered it but it was hard. Tie a string to the wrench just in case. God Bless.

[@AldenPez]

Thanks for this video I will be removing the trim panels like this soon to run some 1/0 power wire for a sound system

[@josephprzechocki5479]

Nice video. The front blend door actuator is also changeable without removing the dash as the book says - I have done it. Had to remove the radio and the glovebox. One arm in the radio hold, the other in the glovebox hole. There was very little room to wiggle it out but it was doable. A gear-wrench would have been worth a ton on that job too - unfortunately I did not have one, so about a million little turns with a box wrench, got all the screws out. It was tricky getting the new one in but that too was doable with patience. The big news is front is also doable without taking the truck apart.

[@TAaron-fq5vf]

Joseph Przechocki I too had to fix the air condition upfront. That was a struggle. I however for some reason bought a 8 mm ratchet wrench while I was picking up the part. I agree with you it made the job easier. Still was very hard though. Plus my wife’s heart for coming out and helping me

[@cryangallegos]

Great video and great shortcut vs the "official" repair guide. Been putting off this repair since the seasons changed, and we didn't need the rear heat to work lol Just wanted to point out that the ratcheting wrench isn't REQUIRED, just makes it a bit easier. Just pulled mine out with a 3/8 drive AND 1/4 adapter for my 8mm socket. Just had to pull back a little further and CAREFULLY get my crankin arm into the void behind the panel.

[@Christatum411]

Great video but it took me about an hour to get that arm lined up right to get it back in. About to do this job a second time (actuator went back out after about 18 months) and am back to refresh my memory. Thanks

[@scottbuckwald8208]

Perfect video. Easy to follow. I had it done in under 30 minutes.

[@jewl1215]

Would this be the same location & process to change one out in a 2009 Ford Expedition?

[@holmesmarketinginternation1898]

Great video man. After replacing my actuator on the side, I found out I realized the bad actuator was the one on top. I have a 2004 expedition. The side actuator is a D shape shank. The actuator on top is a cross shape shank. So after replacing the actuator on the side (which was still good) I removed the bad actuator on top. I opened the housing on the side actuator (the one I removed) and used the good gears to replace the bad gears on the bad actuator on top. Pretty simple fix. Just note the position of the shank before you open the housing.

[@steffenierawlings9353]

Great video. I have a 2013 Ford Expedition. I ordered the part for the 2013 Ford Expedition but be aware that there are several different types of these actuators in the HVAC System in a Expedition. I purchased the one which was supposed to fit the Dual Zone Automatic Temperature Control for the Lower and Upper Air Mains. The actuator that I needed is the HVAC Heater Blend Door Actuator Auxiliary (passenger side next to the 3rd row - the lower actuator). The actual A/C Rear unit in my 2013 Expedition looks just like the one in the video except your auxiliary label say "EXP AUX", mine says "2009 EXP AUX" guessing that the 2009-2013 are the same. Also the wheel base of your vehicle can determine which part is needed. Still haven't figured out which part is needed because if I google the part numbers on the unit 262 11114132 it leads me to the Dorman 604-260 but is says it does not fit the 2013 Expedition XL. I even searched by VIN. The search by VIN says I need the Dorman 604-277 but if I search by 2009 Expedition is says I need the 604-260. So I obviously have a 2013 Expedition with a 2009 Auxiliary, is that normal? I will probably purchase both parts and see which works even though, I'm thinking connections might be different, even if the actuator stem fits into the auxiliary. Any advice besides pay a dealership $$$ to install a $20 part? Thanks again for the guidance in video above!

[@unoefxz]

Great vid! it is fixed!! blowing ice and no more clicking!!! PS: loved watching the dog, mine is all about field trips IN THE TRUCK!!!!

[@FenrirsBite77]

Awesome video ! Thanks for your thorough and simple explanation, just saved a lot of $

[@TK-431]

Great video, and I love your step by step approach. Do you have any advice for changing the front actuator on an 04 Lincoln Navigator?

[@watershed44]

So who DID NOT like this video????? Probably some dealer principal/owner. hahaaaa.

[@pisacksen]

Great video, changed both blend doors in one shot. Everything clicked back together. Awesome💥

[@minnawalker7058]

This was really helpful for my 04 expi ❤❤❤you saved me a few dollars and lots of time on this by watching your video

[@juansupreme]

I got another blend door (I Think) issue. Got the 2005 Expedition 9/2015 hot and cold worked well in the front now it's just cold air(rear hot and cold) I replaced the front actuator (I used old front actuator in rear blend door, perfect fit) as another one of your videos stated(easy thanks) but still get cold air. SO! how can I cut into hvac box and manually move blend door(it's cold outside) till I can replace it?

[@jessewhite6653]

Thanks for the video. Replaced mine and works fine. I have a leak in one of my rear ac hoses and was wondering if you could show how to fully remove that quarter trim piece so I can get full access to the area and figure out which one is leaking? Mine is a 05 Eddie Bauer. Any thoughts on which hose to look at first?

[@mjsummer]

Hey just wanted to tell you that your video was awesome. Followed the links and ordered my part and tool. I was done in less than 30 minutes. Thanks a ton. Fixed it right up.

[@FordTechMakuloco]

+mjsummer Nice!!

[@mjsummer]

+FordTechMakuloco so it works but it is intermittent. I did not replace the actuator that changes from floor to ceiling though. That one does make a popping noise. So even though I never use it in the floor could that one be causing my ceiling air to be warm sometimes. Like I said. The rear ceiling air will blow super cold 50% of the time. I know the actuator that I did replace is not binding because I checked it like you said before installing the new one

[@altascene]

OK, so right off the bat, great info! This video, along with the one for the air direction actuator, helped me get my rear HVAC working right! Caveats? Yes. The screws are a bitch to reach, the the flex-head ratchet would have made a big difference. Plus, there was an extra screw on the bottom of my actuator (4 screws instead of 3). This was an unexpected surprise. Heads up to anyone planning on using the Dorman 604-277. The shaft on this model is larger than the OEM unit. I had to file it down on the three flat sides, and was finally able to get it to fit. Patience, and trial and error, got me to a final solution. As other units are available, you may want to factor this in to your planning.

[@jacobmunoz9104]

Hey Makuloco! You're the man. I love your videos. You've saved my butt multiple times. I have a question. Would the repair be the same for a 2005 6.0 Excursion? I'm getting AC in the back but no heat. Winter is approaching and my kids need to be warm back there. Thanks buddy. Keep making great vids!

[@wolfmtns]

GREAT demo! Exactly what I needed. you da man

[@Josh-oe4ex]

Dude, THANK YOU. Simple fix. I was able to fit a 1/4" ratchet down there and it was much faster, didn't need an offset box-end ratchet wrench(although i had one(). The bottom most fastener was unfortunately a philips head screw! Not an 8mm like the other 3. I was still able to use my ratchet with a philips attachment to pop it out. I did NOT put it back in tho, lol, 3 bolts will suffice! You made my troubleshooting that much quicker and better yet gave us the part number AND link. So like 30 bucks and 30 minutes: problem solved.

[@dannydimatulac8885]

Thank you so much and I have saved a couples of hundreds from the mechanic

[@Schiavoni85]

Thanks man this actuator gave me turrets for about a year. I don’t know what kind of camera you got but I’m getting one

[@TheHeshgoodman]

Cool thanks for the video I'm having the same problem with my 06 Ford expedition

[@Rocketsong]

Just did my 07 Expedition EL. This really helped. The 07 has Torx screws instead of 8mm. It also has two actuators right next to each other. I changed out the rear one and the back now blows cold again. What does the other actuator do? When we have it on rear control the pressure is slightly lower than when the driver has master control. Do I need to change the other actuator as well?

[@rainylakewalleye]

Excellent video!! Thank you...

[@BlueLighter26]

Problem solved, rear air service is working now. Thanks so much brother!!

[@SpeedMerchantChevelle]

Thanks!! Still have my 2007 Lincoln Navigator and needed this video (same). Just FYI...when I replaced the one in the video, I still had the same clicking noise as before. Apparently there are two of these inside the panel. The one I needed to replace is right behind the cup holder. So you don't need to remove anything but the cup holder and the flat tray. Thanks for the video!!!!

[@EngineeredWoodworkingandDIY]

I watched this video and then ordered the part because I heard the tapping flap in the rear. After replacing the part while watching your video. The flap still taps when I turn on the rear air. Do you have any suggestions on what to look at next?

[@jesusruiz5201]

@FordTechMakuloco is the part for the rear blend actuator the same for the front one you did? I have a 2003 ford explorer xlt, thanks man!!

[@klc317]

Good video! I like your shop helper too!

[@KK-cb3bi]

Great videos. Thank you for this. Really appreciate this.

[@shaunspellman2856]

Thank you so much for this!! I will change mine very soon!!!

[@michaelgordy6283]

Hi. Back again. I went ahead and ordered the part # YH-1767 for my 03' Ford Expedition XLT 5.4. This one is the one on the side. I Got that. It felt liked the other one on top was making a noise as well as going by feel. The part # I though that was frequently bought with the other one was YH-1743. Also got the ratcheting wrench as well as the TEKTON 5873 Door Panel Remover. Hope you can give me the positive outlook I'm expecting. Sure hope to hear from you soon!! BTW. I really enjoyed your video which inspired me to do this job myself. Thank You!

[@davel144]

Thank you! It really helped me, both videos.

[@JohnnyUtah488]

My exact issue. Thanks for the high quality info!

[@stevencook1709]

My actuator has 4 screws holding it down! Took awhile but finally got it done. Only replaced 3 screws hope that is ok. The little flex ratchet wrench is well worth it.

[@juansupreme]

Thank you great video, after following your steps I found that it was the one on top not the side, but still you got me to where I needed to be "and for that I thank you".

[@FordTechMakuloco]

+Juan Carlos Yup I have videos on both

[@256juggalo]

+FordTechMakuloco I noticed at the end you tested the diverter door instead of the blend door wouldn't you switch from warm to cool to test the blend door?

[@user-ym8wg9tu1w]

+FordTechMakuloco your expedition is really clean props to you man

[@andrewgregory8856]

Thanks man for helping me out your video is great and helped a lot

[@curiosity2314]

Nice, Ford Corp really lost a good man. I could see that you were more comfortable here which is a great thing. Continued great luck with your new venture..

[@FordTechMakuloco]

Thanks I am not the best tech out there but pretty darn good. Good enough anyway.

[@curiosity2314]

FordTechMakuloco One that can do it and show it is the best tech out there.

[@michaelchapman4261]

FordTechMakuloco is there any other reason why the rear ac won't work? It blows out warm air just not cold. The front AC works fine. Thanks

[@myothernewname]

Curiosity, I think the back has a filter for the orifice. I'm a residential and commercial HVAC tech, never worked on cars, but was looking at mine a few days ago.

[@arelimejia1984]

FordTechMakuloco can there b a freon leak back there I'm hearing a hissing like a leak sound does it have any ac lines my vehicle is leaking freon for sure checked the front with ac freon dye and only saw the dye in the high and low ports.. 1 12 oz can of freon lasts about 2-3 weeks because I can feel the rear vents not cooling

[@prferreiramf]

thank you for sharing the video, do you have one for abs light on?

[@nktwrk73]

I got a dog in my panels??? awesome vid, I have a 05 Lincoln Aviator and you just saved me big.

[@Mody_666]

Thanks for your videos. Very useful. I have a 2008 Expedition Limited EL. The AC control unit is stuck on auto. Is this a full AC module replacement or just the controller card replacement? Do you have a video replacing either? Thanks

[@mikimiki195]

As always great money saving video Thank you so much

[@nicolasruan8888]

Thank You so much for your help .

[@JUANJIMENEZ-df5jk]

great job. you save me a ton of money. thanks for your help.

[@turrubiartes9]

Thanks for your videos . I learned a lot

[@jaimerodriguez669]

Thank you for the video I now fix the problem with the rear ac and heater on my expedition my expedition has 240887 miles 4.6 2V great engine my brother F150 4.6 2V 4X4 has 359.000 miles and still running strong

[@onefeather7890]

Excellent video! Thank you.

[@mohammedhumidat3852]

Thank You so much, please tell me how to clean the front AC refrigerator in the front dash for Expidition 2005 as the air flow is week and not cold.

[@leoplese8272]

Once again a great video with many tips to do the job right.

[@PuroPinchePancakes]

Great work man! That was very helpful

[@ServicioFrioAires]

congratulations. Very good explanation

[@gufftaylor7362]

Thanks for the video. Definitely a help when pulling all the panels and trim parts. This was for a 2005 Expedition. And in my case, I also had 4 mounting screws to remove. The two you show removing were the easy ones! Ha! For me the Motorcraft stock was YH1749 with a Ford part # 3L1Z 19E616 AA. I took the old part to Ford to insure I got the right one and came away with the same part number with the exception that the two last letters were AB on the new part.I did remove the old "D" shaft from the broke unit to check for unrestricted movement of the Blend Door, noting the relative position of the flat side of the "D" when inserting and removing the shaft. This aided in replacing the new unit. Sure enough, several teeth of the smaller gear were scattered in the grease in the broken unit.

[@gufftaylor7362]

An added thought. Several months ago when we noticed the clicking sound, I removed the cup holder and top tray to find which unit was making the clicks. Reach down and lightly touch the blend actuator and also the distribution actuator. You can feel the one causing the clicks. I unplugged the suspect actuator to confirm the correct one. After all the naggin', I finally broke down and replaced it in cooler AZ weather! Now, on to fixing other nags!

[@Skyefuego]

I'm glad I found this channel!!

[@FordTechMakuloco]

+Skyefuego We are glad you are here!

[@Skyefuego]

Every problem I had with my expy you always have the video for it. Thank you.

[@dstgean]

Thanks for the video and the part number!

[@cheesecurd8557]

Thank you AGAIN for your awesome videos!

[@joetoscano3875]

Hi there..it was a great video...your video shows three screws..Mine had 4..and the bottom one was a real bear to get out, my wife had to get her skinny hands in there...other than that it was great. Originally I thought it was the top actuator. I purchased it, and put it in...still making the noise...I opened it up and noticed a bunch of teteh broken...probably was going anyway..SO i replaced both. Amazon sent me the little short 8mm wrench, and I used electrical ties to make an extension for it..it worked. thanks

[@MustafaLaswe]

Thanks, do the rear ac have a filter? and how to replace it please? do you have any video showing how?

[@cris751]

Thanks my friend for the video

[@ncurry84]

Do you have a video for 07 and newer or is it the same concept???

[@michaelgordy6283]

Great Video!!! Best I have seen! My question is what is the actuator there on top? I believe both of mine are clicking. I know the one on the side is for sure. I could feel it as well as hear it, however it also seems the one on top is clicking to. Does one operate the air and the heat on the other one? Thank you. Hopefully you can assist me with my issue.

[@edwindon22]

This is very helpful video. Do you have a video how to trace the leaking air conditioning? I hear a breading like psssss sound every few seconds while the aircon is on. I can hear it from the rear. Mechanic only top it up with coolant but will ran out after a month.

[@FordTechMakuloco]

+Edwin Banaag A/C dye is the only way.

[@waterman308]

Ahhh! where were you 3 years ago!!! took my 03 Expy panels all off... and found out that Ford dealer gave me the wrong actuator. got the one under the cupholder. Grrrr. had to go back, re order etc. several days with the back of my Ex looking like it was rescued from a chop shop :)

[@milesgillie3342]

I replaced the rear mode actuator several times in my 2005 Expedition with a Dorman part from Advance Auto. After a number of months a gear tooth would break and I was back to the clicking. Finally removed the electrical connector and super glued the actuator so the air came out of the roof vents...tired of replacing it. Do you think this is due to using the Dorman part? If I had used Motorcraft would I have better life or is something else going on?

[@ryanhardin5166]

so I have a clicking sound where the blend door actuator is, but cold air is getting back there ..would that make it the mode actuator? the one where the whole panel needs to be removed?

[@csbarnett4005]

I appreciate the video to take apart the panels. It worked great. I have a 2003 Mercury Mountaineer and the assembly is on the drivers side. Would you happen to know what else might be wrong, I disconnected the actuator and still heard clicking coming from the black assembly box the actuator was connected to. I cannot find any other information out there for my car. If you could help that would be great before I go any further or pay 100's of dollars to have a mechanic do it. Thanks.

[@cabebe21]

great video and very helpful. have you tried or have a video for 2006 ford explorer eddie bauer 4.0L. The actuator are very hard to get to? any help you can provide is greatly appreciated