my blend door is starting to do a flapping noise for a few times then quits. i think its stripping. i did the diagnostic to see which it is , its the top of the dash in the middle. the only problem it other that disableing the defroster nothing else seems to change. does it only select air condition or defrost. so i left it unplugged 1\2 of the summer for no flapping air and now in winter i plugged it back in for the defrost and dont use it on air and no flapping. so what does it do. and am i loosing cooling or some thing with it unplugged in the summer. i hear its hard to replace that motor
thanks rick

 

It's not hard, or even a nightmare really, it's just... odd. Weird bending of your arms/hands to get to things and if you don't have the right tools, oh yeah, it's gonna be stupid. Get the right tools, it's nearly a snap.

From the manual, the blend door actuator replacement instructions:
http://iihs.net/fsm/?d=336&f=Tempera...20Actuator.pdf

You'll want a sort of wobbly socket setup or maybe a flex head ratchet wrench (7mm, mind) to get those screws, but the blend door motor is 'right there' when you pull the glove box door down. You can then verify by putting your hand on the motor as you do whatever makes it crackle, you'll feel it in the motor. Swap that one out and that will get ya on your way!

Here's a video from FordTechMakuLoco (worry not about the not-05-09, these are the same for all S197s). This basic procedure can be done for any of the blend door motors. You do NOT have to remove anything besides the glove box door for the right side ones, and even then, it might not be necessary.

I've seen other videos by Chasing Mustangs on youtube, and the problem with his is he's doing a LOT of extraneous stuff that while maybe making it easier in some ways to get things, they're just so much more work than you really need to do if you have the proper tools. He also does some sort of reset which also isn't required. Not sure why he's decided to do these things, but they're here if you want to watch them, as they show where things are and that's good:

Examine the location and understand the wobble/jointed things you'll need and get them. Say a wobble head ratchet wrench, like this:
https://www.homedepot.com/p/TEKTON-7...7107/207112504
As an example, not an order, mind. You'll need the 7mm wrench/socket to get the screws out though.

Here's the other three doors. Note airbags and instrument panels do not come off in the instructions. I'm not saying it's incredibly easy to do them, but they're not all that difficult, and they'll just work.
Air Inlet Door
Defrost Door
Panel Floor Door (the one on the driver's side)

I hope that helps. Good luck!

/Note: I can certainly understand the 'nightmare' side of it.. if it was a Fox or SN95 or such. THOSE blend doors were behind the plenum at the firewall, and buried up in there *bad*. You had to remove the dash to do that one. And worse... it failed 'hot'. Which in Houston is just... no. This redesigned plenum setup is much nicer, all the motors are accessible without removing dash at all. Only dash removal item is the plenum to get the cores out, and let's hope that doesn't happen anytime soon..