Climate Control - Improper Operation
91ford04
^ AIR CONDITIONING - EXCESSIVE AIR BLEED FROM INSTRUMENT PANEL REGISTERS - TRUCKS BUILT AFTER 2/23/87
^ AIR CONDITIONING - FLOOR - PANEL AIR DOOR SLUGGISH OPERATION - TRUCKS BUILR AFTER 2/23/87
^ HEATER - EXCESSIVE AIR BLEED FROM INSTRUMENT PANEL REGISTERS - TRUCKS BUILT AFTER 2/23/87
^ HEATER - FLOOR - PANEL AIR DOOR SLUGGISH OPERATION - TRUCKS BUILT AFTER 2/23/87
Article No. 91-4-12
LIGHT TRUCK: 1987-91 AEROSTAR
This TSB article is being republished in its entirety to extend the model year coverage from 1987 to 1991 models
ISSUE: Excessive air bleed from instrument panel registers when in the Heat, Mix or Defrost modes may be caused by a sticking floor-panel air door lever or a distorted floor-panel air door. This may cause improper operation of the air conditioning/heater system when changing the air discharge pattern from one mode. to another, such as Vent to Heat, Mix or Defrost.
ACTION: If a binding condition exists but the floor-panel air door does not appear distorted, install a new floor-panel air door lever. Refer to procedure A. If the floor-panel air door is distorted, install a new floor-panel air door and lever. Refer to procedure B.
PROCEDURE A
1. Remove the upper instrument panel finish cover. Refer to the 1988 Aerostar Shop Manual, Page 18-06-7 or the 1989 Aerostar Shop manual, Page 12-02C-7 for service details.
2. Disconnect the vacuum motor arm from the floor-panel air door lever, located on the top of the plenum.
Figure 1:
3. Remove the floor-panel air door lever, Figure 1.
Figure 1:
Figure 3:
4. Lubricate the new floor-panel air door lever, (F19Z-18N272-A) with silicone lubricant, (COAZ-19553-AA). See Figure 4 for lubrication areas.
5. Install the floor-panel air door lever.
6. Attach the vacuum motor arm to the floor-panel air door lover and secure it on the lever with one spring nut (383358-S), Figure 1.
7. Check the operation of the door and be sure that the door lever does not pinch any vacuum lines during operation, Figure 3. If necessary, reroute the vacuum lines away from the area of concern.
8. Install the instrument panel finish cover.
PROCEDURE B
1. Remove the heater core cover from the plenum. Refer to the 1988 Aerostar Shop Manual, Page 18-06-21 or the 1989 Aerostar Shop Manual, Page 12-02C-21 for service details.
2. Clamp off the heater hoses.
3. Remove the heater core from the plenum.
NOTE: DO NOT SPILL COOLANT WHEN REMOVING THE CORE FROM THE PLENUM.
4. Remove the upper instrument panel finish cover. Refer to the 1988 Aerostar Shop Manual, Page 18-06-7 or the 1989 Aerostar Shop manual, Page 12-02C-7 for service details.
Figure 1:
Figure 2:
Figure 4:
5. Disconnect the vacuum motor arm from the floor-panel air door lever, located on the top of the plenum.
6. Remove the floor-panel air door lever, the floor-panel air door gear and the floor-panel air door from the plenum, Figures 1 and 2.
7. Lubricate the new floor-panel air door lever, (F19Z-18N272-A) with silicone lubricant, (COAZ-19553-AA). See Figure 4 for lubrication areas.
8. Install the floor-panel air door (E79Z-18A559-A), floor-panel air door gear, and floor-panel air door lever, (F19Z-18N272-A) on the plenum.
9. Attach the vacuum motor arm to the floor-panel air door lever and secure it on the lever with one spring nut (383358-S), Figures 1 and 2.
Figure 3:
10. Check the operation of the door and be sure that the door lever does not pinch any vacuum lines during operation, Figure 3. If necessary, reroute the vacuum lines away from the area of concern.
11. Install the heater core and the heater core cover.
12. Install the instrument panel finish cover.
13. Re-connect the heater hoses.
14. Check the coolant level.
PART NUMBER PART NAME CLASS
E79Z-18A559-A Floor-Panel Air Door B
F19Z-18N272-A Air Door Lever B
383358-S Spring Nut - Pkg. of 30 BR
COAZ-19553-AA Silicone Lubricant B
OTHER APPLICABLE ARTICLES: None
SUPERSEDES: 90-23-14
WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
910412A Install Lever & Lubricate 0.8 Hr.
910412B Install Door & Lever 1.6 Hrs.
DEALER CODING
BASIC PART NO. CONDITION CODE
18A559 02
OASIS CODES: 208000, 208300