Blend Door Housing?

2014 FORD FUSION
170,000 MILES • 2WD • AUTOMATIC
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NOTGOODWITHCARS
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Having issues with my passenger side A/C blowing cold air and the driver side blowing warm air. Obviously, the blend door actuator, which I replaced about two weeks ago and everything worked correctly afterward (cold air both sides or dual controls). Then today out of nowhere the same issue arises with cold on the passenger and heat on the driver (I have my controls set to push out cold air). I take the blend door actuator on the driver side off completely, then plug it in and push the ignition in without the brake and the motor turns (I believe this would mean this new blend door actuator is not broken). However while doing some investigation I notice that the blend door housing (that the actuator fits into) that has the white gear with one area missing a tooth is actually quite loose. Is this supposed to be loose? Or has something come undone behind and is needing to be popped back into place? Should I try purchasing a new blend door actuator and seeing if that solves the issue? Any help would be appreciated! Also, I am trying to upload a video I have of me moving the part around with a screwdriver so if that is not visible please let me know so I can look further into providing that!
Jul 29, 2025 at 11:06 PM
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NOTGOODWITHCARS
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Here is a video of the part!
Video (Click to enlarge)
Attached Media
Jul 29, 2025 at 11:09 PM
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STRAILER
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Thanks for the video. the receptacle for the bleed door actuator looks loose, like it is broken. But I would try a replacement actuator in case you got a defective unit, was the gear that loose when you replaced the actuator the first time? Also, turn the system on and work the gear back and forth to see if the temperature changes, this will help see if the blend door is broken and the HVAC plenum will need to be removed for repair. Please upload pictures or videos in your response.
Jul 30, 2025 at 10:28 AM
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NOTGOODWITHCARS
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Ken, thank you for your reply! Yes, I moved the gear back and forth and the driver's side A/C went from hot to warm but definitely not as cold as the passenger side. If you were to look at the gear straight on and imagine a clock, 10 o’clock was very hot and the farthest it would move towards the cooler side was maybe 1-2 o’clock (moving clockwise from the 10 o’clock position). Thinking maybe something is bound up behind where the gear sits as it IS adjusting the temperature but not adjusting far enough to achieve the temp I am wanting. I will look into taking the receptacle cover off and getting videos or images this evening for further investigation. Would you have access to a diagram of what it is supposed to look like behind the blend door actuator receptacle so I can quickly confirm if there is an issue? Thanks!
Jul 30, 2025 at 10:37 AM
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NOTGOODWITHCARS
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Also apologies I do not remember if the gear was that loose two weeks ago, I wish I had so I would be able to get a quick diagnoses! Just strange it would work for two weeks then quit out on me again.
Jul 30, 2025 at 10:40 AM
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STRAILER
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Yep, it sounds like something was drop down inside of the HVAC system vents such as coins, tooth pick and an ink pen. You should hear the door close lock to lock. This is what wrecks the blend door motor as well.
Jul 30, 2025 at 4:43 PM
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NOTGOODWITHCARS
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Unfortunately so, I’ll update once I get the plenum panel removed and get a better look.
Jul 30, 2025 at 5:34 PM
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STRAILER
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Sounds good, thanks for the images, videos :)
Jul 30, 2025 at 5:38 PM