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

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.

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!

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!

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.

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

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.

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!

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.

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.

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.

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

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!

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 !!!

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

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....

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.

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.

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.

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!

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.

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

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?)

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

Since there are two actuators be sure to know which one is clicking before replacing it. One way is to touch it with your fingers to feel the click. Another way would be to unplug it to see if that stops the clicking.

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

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

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!!

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

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.

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.

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

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

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.

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.

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

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

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?

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

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

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

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

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.

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!!!!

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.

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!

Excellent video!! Thank you...

My exact issue. Thanks for the high quality info!

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

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.

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".

You're a lifesaver. Dealer said I needed a new rear AC wanted to charge me over $1,500 bucks. Turns out it was those two Motors that were out. Went to O'Reilly's paid 140 for both together took me 45 minutes to install done. Works like a champ.

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.

Having trouble finding rear txt valve on 07 expedition any ideas?

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.

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

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

Thank You so much for your help .

GREAT demo! Exactly what I needed. you da man

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.

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

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?

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?

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?

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

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?

I have a 2010 expedition my rear ad not blow air it did days before what do I need door tempeture actuator or air distribution actuator?

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

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.

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!!!!

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

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

Took about an hour and only $75 for OEM part. Thanks!

@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!!

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..

Thank you! It really helped me, both videos.

Video was a great help. Next time warn a brother to not drop the wrench, then to also not drop the flashlight being used to look for the wrench;-)

i unplugged ours a few months ago and now just ordered one. I've put it off long enough lol

Will this fix the middle vents seems I have air in rear but air doesn't come out middle roof vents

Can you tell me how to remove the two rear climate control knobs out in the back I have a 03 expedition and I want to replace the bulb in the knobs. Can you help me. I can’t get the trim off to get to the screws to take them out the trim is really on there

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

Good video! I like your shop helper too!

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?

I need know about my ford explorer 2006 for rear HVAC temperature blend actuator need to fix! i w

Excellent video! Thank you.

I got the 8mm wrench and bought an actuator that's supposed to fit but the long pin isn't the same shape as the original. Does that matter? I was able to get the old one out but can't get the new one in.

Thanks for the video and the part number!

As always great money saving video Thank you so much

Help!! I have the old part out but I cannot get the new one back in. I cannot get it to line up. It has the D shape end. Any suggestions?

Hello I was wondering if this is the part needed to change if I'm not getting hot air in the rear everything else works fine AC but went I turn on the heat its just cool air coming out the rear thank you

Thanks my friend for the video

What causes my 2006 Lincoln Navigator to knock a loud repeated thud thud sound when I turn the rear AC blower dial up? The sound comes from the back or the ceiling? Thanks!

So a l all the clips that connect to the window that hold the panel broke do you know where I can get rplacements?

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

I don’t know if this was already post on here but on my 05 expedition Eddie Bauer there are 4 screws, one on the bottom of the actuator and I really think that panel that the cup holder sits upon needs to come off to be able to get to the 4th screw to take the screw out. Unless I’m incorrect?

I have a 2007 Freestar, no air being blown in the back. Is there a blower with resistor that can be replaced back there? I hear a loud click each time i turn up the rear fan speed on the controls. Thanks!

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

Thank you! That clicking was really begging to get to me.

If its clicking at random times how can you figure out which one is clicking to replace?

I have a 2015 Expedition EL and it appears it has 2 separate blend door actuators, right next to each other. Is that correct ?

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?