Does your vent selector stick? Have you broken the cables? Read on,
 

So I think I have a solution to this problem. I can't be sure yet, but everything is looking good so far.

But first I want you to answer this question, Do you have a cabin air filter in your car? (if you didn't install it, chances are you don't)



So my blower motor finally died. It had run enough to ware the brushes down to nothing. So I installed a new blower motor.
But first I thought it'd be a good idea to blow the dust out of the vents. Thing is there wasn't much dust that came out. But boy oh boy was there leaves, sticks and other tree debris, all in little bits.
Hmmm.
Seems that leaves and such were chopped up by the blower motor and stuck on the back side of the heater core.
In the process of blowing all this out I rotated the vent selector back and forth. The more junk that cam out, the freer the knob got.
So it seems to me that debris is the main problem as to why things get sticky and break.

Now, I haven't had a cabin air filter in my car ever. That is 11 years. Which time wise seems to fit with others I've seen with similar problems, and no solution has been posted to my knowledge.

To prevent this, I'd say a cabin filter should be used in every car.


To get the junk out you'll have to remove the blower motor. Not difficult, it's only 1 electrical connector and 3 screws. But it's an awkward angle to work at. Stretch before wiggling under the dash so you don't cramp up.
Grab the air hose and blow all the debris out. Change the direction of the vent and blow again. Continue this until you feel you got most everything.
Should be good for another 10 years or so.

Best of luck.


Here is the file on how to remove the blower motor --> http://www.filedropper.com/focusblowermotor

This is great info. All focus's can use a cabin air filter it is located under the cowl by the wipers. I think only the first model years actually got the filters installed from the factory. After that I haven't seen a single one with it, but they all have the spot to put them on.

05-07 have no filter- on purpose. An earlier model Foci filter caddy can be substituted in place of the metal mesh screen if you can successfully remove the foam glue holding the screen in place. Something else will have to be used to seal up the filter caddy. Something like automotive window adhesive will work. Adhesive foam rubber should work if it's heavier duty type that will withstand high and low temps. The good thing is that the factory part bolts on the same way so there's no problem with having to drill holes.

Here is a link for the broken cable fix:

http://www.focusfanatics.com/forum/showthread.php?t=293932

The selector mechanism is by the driver's right knee, and you can try and move it there. I haven't had to dive into the heater core on my Focus yet, so I can't give you any specifics on that.

My 07 has a problem with sticking too.What I found is not in the cables or blower housing but the bled door it self.The rubber seal Ford uses gets sticky over time and doesn't release from the housing where it makes contact.If the center vent and duct is removed you can just get your hand to the top of the blend door and you'll feel it stick.As a short term fix spray some silicone spray on the blend door and work it limit to limit several times.This will last several months then it will need to be done again.

I have this problem also... And it drives me nuts... Never thought to go in thru the blower housing.... I will try this if the weather ever breaks here! Thanks so much!

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