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Thread: How To: HVAC (Climate Controls) Broken Cable Reply to Thread
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Topic Review (Newest First)
04-18-2017 08:13 PM
amc49 You can avoid selector extreme positions at the 2 ends of the HVAC cam slot but not at the middle positions, you have to cross over 2 sticky positions there as well. There are 4 sticking points in all.

The lowest shaft you see in the HVAC airbox is the one that causes all the trouble, it sticks solidly in both extreme locations, but those get used twice each in the cam action to make the 4.
04-18-2017 01:57 PM
Earl54 Two cents from a new user. I bought a 2007 Focus, 133k miles, for my son to drive to school. It had the usual stuck selector door. I had read about cleaning the door with silicone. I have a solvent, sol-u-mel, made by the Melaleuca company, that is pretty good at removing sticky stuff, but not too aggressive. My wife has some small syringes for refilling ink in printer cartridges. I took off the panel under the steering wheel and disconnected the cable. I tried shooting three syringes full of the solvent, at various angles, down the center vents, where it might run down and hit the door. (In retrospect, I probably should have tested the solvent on the plastic of the HVAC assembly, but didn't.) After each shot, I worked the doors from the actuators on the side of the HVAC box. Put it all back together, and let it sit overnight with the windows open a bit to let the solvent smell dissipate. The doors to divert the airflow worked, but didn't move well. Then two weeks later they stopped working. I believe the cable was already damaged. I ordered and installed a new cable, thinking things would be stuck again, but no binding. That has been a few weeks ago, and it is still working well. I told my son to keep the selectors away from the extreme positions, where they would be more likely to bind.
I'm not naive enough to think it is a permanent solution, but optimistic enough to hope it gets him by for a while. And it was certainly easy.
08-23-2015 03:57 PM
sailor Well, you say A/C works - that means the fan is working.

Only blows on the floor no matter how the knob moves - knob isn't moving anything.

Earlier posters said the '05-'07 had cables like the earlier cars (some other actuators came along later) so it looks like a cable failure.

You can peek at the cable connections to the HVAC box under the dash on the driver's side of center to confirm, pics in that link I posted.

How "stuck" or not is yet to be determined.
08-23-2015 11:07 AM
longarm Thanks for the links. But from what I described, does it sound like it's the doors sticking, the cables broke, the blower motor quit, etc...?
08-22-2015 11:52 PM
sailor You found a couple threads, here's another stickie that might help:http://www.focusfanatics.com/forum/g...bles-read.html
08-22-2015 11:25 PM
longarm So, I find myself wondering exactly what's wrong with my 07 ST heater controls. It was always a bit stiff, from the factory, and sometimes was worse, depending on the weather IIRC. My son has been driving the car for about a year now. I just got in it the other day and noticed that the only air that is coming out is on the floor vent. It doesn't matter what position you put the knob on, it's only coming out on the floor. And the AC still works.

I have no idea how long it's been like this. I keep telling my kid to let me know when something doesn't' seem right about the car, but he's a teenager. Great kid, but forgetful. Does anyone have any ideas? Any help/advice would be greatly appreciated. Thanks in advance.
05-27-2015 07:28 PM
sailor For the Temperature (blend) door IIRC some used silicone spray to help avoid it sticking at full travel (or just don't move it all the way).

For the location selector I leave it off the center position where it changes over from floor/dash to opening the defrost vents, and move it easy through that position where it can bind if moved fast when changing from left to right side positions.

So far no cable breakage (cross fingers).
05-27-2015 07:17 PM
nization Does anyone know of any modifications to make to prevent the doors from binding up? I just replaced the broken cables today and was disappointed to find the box still had bound doors. I was able to free the one by hand and it's moving freely...ish now, but as others have stated already, it will eventually bind up again next time I select dash or windscreen.

Cables were a breeze, but I'm afraid the HVAC box doesn't look to be so simple to remove to disassemble....
10-08-2014 11:08 AM
timinks2 Just performed this job on my 2006 Focus, didn't have to take the seat out (i'm 6'2 and a big guy) and it took me about 20 minutes! The only tools I needed was a Flat-Headed screwdriver, and a 5/16ths nut driver. I did take some lithium grease and put on the door slider and any rotating point that i could find. Hopefully the one I got from the salvage yard will last as long as the one that was in the car from when i bought it new (yes, 8 years of reliable service out of this car) but we shall see! if nothing else they're 6 bucks at the salvage yards and very easy to replace.
10-08-2014 03:56 AM
Tklein My 06 zx4 would be identical to your 05; And I didn't have to take out the seat either ! And you"re right, it is a poor design and they sure made things better 30 yrs.+ ago !! Thanks for your reply !!!!!
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