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Old 07-30-2018, 10:06 AM   #51
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I installed the upper stop using 2 screws right through the plastic (I blunted the screws to avoid damaging the door and I used slightly thicker screws to spread the contact point).....I put 1 screw where the one is pictured in Post#21 and one opposite it on the other side of the ribbed section. I had a friend turn the screws while I manipulated the blend door lever...as soon as I felt it touch I had him screw it another (approx.) 1/4 turn to just barely take the door off the sticky point....it seems to work very well.... the door doesn't seem to stick on the bottom so I didn't put the side stopper in.

Thanks again Hamlorac and the rest for posting this helpful and money saving tutorial....
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Old 10-10-2018, 11:01 PM   #52
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Quote:
Originally Posted by hamlorac View Post
Ref. Sticking vent selector heater controls on 2006 ZX5.Remove drivers under dash panel,loosen hood cable nut and slide off, unclip data connector and set panel aside.Remove 4 screws from selector control ,cables attached, and let hang down. Unhook the black selector gate and feel the action of both front and rear flaps.The main culprit is the flap closest to the radio so as you move that flap you should feel the sticking or stuck condition at both of its far end positions.A deformed internal flap seal causes this jamming effect, so here follows my humble solution, that involves adjustable end stops.I used a 1/16" aluminum strip 3" long and bent up one end about 1/8" at 90 degrees and mounted it on the heater box with short self-tappers against the link of that flap to provide a forward stop.This stop should be carefully positioned so as not to allow the flap to drop into its sticky resting place.If you are close the aluminum is easy to bent so as to get a finer adjustment.The next step is to remove the radio surround panel,disconnect cigar lighter,remove the radio, pull two cables and set unit aside.Drill a hole in the heater box and install adjusting bolt bracket as shown in the photo. It is important to adjust these end stops as minimally as possible or the mechanism will bind. After the two stops are mounted a final check before reassembly is to install the black selector gate back in position and work "by hand" the mechanism through its full motion to confirm that no stickiness occurs in either of its end positions and that it transitions smoothly through its various modes.Although the flap is not technically as the designer intended, my air flow is normal and the cable controls work properly. The cost of materials is negligible and the labour maybe two hours work .The Ford car company does not need any more of our hard earned money so I hope this helps some other physically challenged heater boxes. The cost of materials was negligible and took maybe 2 hours, with a low difficulty scale.
This ^ right here looked like the easiest fix that I have found, so... To see if the fix would solve my problem, I simplified this even more.

I drilled a hole in my plastic heater box in the location shown. Then I put a fine thread bolt (big, like a 3/8-24) up against the hole and drove it in with a socket, extension and ratchet. It's only plastic, so the bolt can cut its own threads. That's it. No bracket, no locknut. I figure if the bolt works its way loose, I can always pull the bolt out and make up a bracket like shown.

Meanwhile - I screwed the bolt in until the control lever started moving and stopped. That was not enough. The door stuck after a little while. So I pulled the radio and gave the bolt a few turns. Since then, the door has not stuck.

I consider it SOLVED.

Thank you!

Last edited by Fourspeed; 10-12-2018 at 01:41 PM. Reason: Typos.
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Old 10-11-2018, 06:13 AM   #53
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Good work Fourspeed. Both you and Reilly have simplified this fix so others can benefit.
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Old 11-26-2018, 05:11 AM   #54
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My HVAC switch is not responding to selecting between defrost/panel/floor, I hope I can find a solution here on this forum.
Thanks to all.
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Old 11-26-2018, 05:15 AM   #55
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My vent switch is not responding when I selecting defrost/panel/floor, searching a solution here on this forum.
TIA
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