Blend door actuator replacement and possible wiring issue?

2004 FORD E-SERIES VAN
124,000 MILES • 4.6L • V8 • 2WD • AUTOMATIC
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NATHAN94
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Only having cold air coming out of the vents in my e250 ford Econoline, previous owner had tried fixing it but ended up cutting a wire which he patched up with a crimp and spare wire. I've replaced the blend door actuator and had no luck (blend door motor didn't even move) so I decided to take apart the old one and fiddle around. Old blend door actuator still moves as when I put it back in after opening it and plugging it in it moves the motor one direction but then stops and doesn't go the other way (Weirdly enough I first noticed it when I had accidently put the motor upside down and when connecting it up again it would do small rotations back and forth in a rocking motion, I think due to being on opposite negative and positive terminals). I can include photos of what I'm talking about and also the cut wire as I removed the previous owner's work to make sure the wires were put back together properly. Any help would be much appreciated as I would love to have heat now it's nearing winter. Thank you.
Sep 19, 2023 at 9:30 AM
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STRAILER
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Let's make sure the wiring is okay from the actuator to the HVAC controller. This guide can help, and I have included the HVAC wiring diagrams so you can see which wires to test.

https://www.2carpros.com/articles/how-to-check-wiring

Check out the images (below). Let us know what happens and please upload pictures or videos of the problem so we can see what's going on.


Sep 20, 2023 at 6:47 PM
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NATHAN94
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Hi there, upon further inspection realized the crimps weren't secured properly and looks like the wire that is cut is the Lt green/yellow wire from the front function selector switch assembly to the blend door actuator. I've twisted the wires together just to see if there is any power but still nothing but wondering if I still need a voltmeter to test the wires themselves?
Oct 10, 2023 at 4:01 PM
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STRAILER
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I would recheck the fuses to see if any are blown after the wiring repair. Please check the pnk/blk wire for power when the key is on.

https://www.2carpros.com/articles/how-to-use-a-test-light-circuit-tester

Please go over this guide and get back to us.


Oct 11, 2023 at 7:41 AM
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NATHAN94
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Checked fuses and they are all good, when testing the power socket for the blend door actuator I only have power from the pink/black wire and nowhere else from the other pins inside the socket.
Oct 11, 2023 at 1:10 PM
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STRAILER
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Yes, that is the only wire that should have power. The black wire should have ground, when testing the black wire make sure the wiring connector is unplugged. Use the test light connected to power for the ground test.
Oct 12, 2023 at 10:36 AM
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NATHAN94
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By power do you mean the positive terminal of the battery or is there another place I can connect for power, my circuit tester isn't very long.
Oct 12, 2023 at 4:16 PM
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STRAILER
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anywhere there is power present will work.
Oct 13, 2023 at 8:28 AM
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NATHAN94
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Okay, i tried from the 12v socket and that blew the fuse, couldn't think of anywhere else so I've only tried from the socket.
Oct 13, 2023 at 8:34 AM
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STRAILER
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The test light clip probably caused a short, can you extend the lead? or you can use a voltmeter.

https://www.2carpros.com/articles/how-to-use-a-voltmeter

Please go over this guide and get back to us.
Oct 13, 2023 at 8:59 AM