A/C Controls - Sticking/Binding
89ford35Article No. 89-23-11
^ AIR CONDITIONING - CONTROLS STICKING OR BINDING
^ HEATER - CONTROLS STICKING OR BINDING
LIGHT TRUCK: 1986-87 AEROSTAR
ISSUE: Sticking or binding A/C-HEAT controls may be caused by a distorted floor-panel air door. This causes the airflow to come out of the wrong outlet(s) and/or excessive air bleed to other outlets.
ACTION: Install a new floor-panel air door, gear and, where appropriate, a lever. Refer to the following procedure for service details.
1. Remove the heater core cover from the plenum. Refer to the 1986/87 Aerostar Shop Manual, Section 18-06 for service details.
2. Clamp off the heater hoses and remove the heater core from the plenum.
NOTE: DO NOT SPILL COOLANT WHEN REMOVING THE CORE FROM THE PLENUM.
3. Remove the upper instrument panel finish cover. Refer to the 1986/87 Aerostar Shop Manual, Section 18-06 for service details.
Figure 1:
4. Proceed as follows:
a. For cable-controlled doors: Remove the black control cable and the control cams from the plenum, Figure 1.
Figure 2:
b. For vacuum-controlled doors: Disconnect the vacuum motor from the floor-panel air door lever and remove the lever, Figure 2.
Figure 3:
5. Remove the floor-panel air door gear and the floor-panel air door from the plenum, Figure 3.
6. Install the floor-panel air door (E79Z-18A559-A) and the floor-panel air door gear (E79Z-18A497-A) on the plenum.
7. Proceed as follows:
a. For cable-controlled doors: Install the control cam and control cable on the plenum. Adjust the control cable to be sure of proper air distribution.
b. For vacuum-controlled doors: Install floor-panel air door lever (E79Z-18N272-A) on the plenum and reconnect the vacuum motor arm to the lever. Secure it on the lever with one spring nut (383358-S).
Figure 4:
8. Check door operation as follows:
a. For cable-controlled doors: Check for proper operation of the door and ease of control lever movement.
b. For vacuum-controlled doors: Check for proper operation of the door. Be sure the floor-panel air door lever does not pinch any vacuum lines during operation, Figure 4. If necessary, reroute the vacuum lines away from the area of concern.
9. Install the heater core and heater core cover.
10. Install the upper instrument panel finish cover.
11. Re-connect the heater hoses.
12. Check the coolant level.
PART NUMBER PART NAME CLASS
E79Z-18A559-A Floor-Panel Air Door B
E79Z-18A497-A Floor-Panel Air Door Gear A
E79Z-18N272-A Air Door Lever B
383358-S Spring Nut BR
OTHER APPLICABLE ARTICLES: 87-15-8
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
892311A Cable Controlled Door 1.5 Hrs.
892311B Vacuum Controlled Door 1.6 Hrs.
DEALER CODING
BASIC PART NO. CONDITION CODE
18A559 41
OASIS CODES: 2600, 2610, 2620, 2630, 2631, 2633,2634