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C2H5OH
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Discussion Starter #1
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
 

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FF's Night Security
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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.
 

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Captain TMI
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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.
 

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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.
 

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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!

Sent from my Galaxy Nexus using Tapatalk 2
 

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Great news.
Mine was sticking and the dealer said that a weak spot of Focus.He have me cables but said to expect the same problem.
Is there a link that shows how to take out fan or is it fairly simple?
If your in a pickle and you need air through the correct vents you can remove partial panel under steering wheel and on the side of radio compartment you can move the lever by hand.Down will force air through vents,up through defrost.
 

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I may have to give this a try when I feel like pulling the car apart again. It's having enough problems that I don't even want to look at it and I'm about ready to drive it into Lake Ontario.

Anywho, mine gets stuck on defrost,and I have to reach up inside there and manually move it. As long as I keep it a notch from full defrost, it doesn't stick.

Almost seems like it goes a little further past where it should, and turning the knob isn't enough to rotate it back.
 

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Here's one, http://www.focusfanatics.com/forum/showthread.php?t=245260&highlight=fan+removal

For an earlier model, and later posts noted some model differences...

Enough general info. to help you out!
Thanks for the link.My A/C cools better on the passenger side vents than driver side vents including the middle vents,passenger side is cooler.

I don't know what part of A/C is in front of fan.Was any debris or built up around or on it that reduce the A/C's ability to cool?

On cool days my A/C works,probe in dash 42-38 degrees very well but on hot days 58-64 degrees.
 

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I got my fan off and I've pulled sub-dash under steering wheel.

I'm going to replace the cable to the air direction control knob so I have to pull the center dash.
Is there a link that shows how to pull center dash to access the 3 knobs,temp,air flow,fan speed?
 

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It just rips off... No screws or anything...

Sent from my Galaxy Nexus using Tapatalk 2
 

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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 tried removing the fan and blowing out the debris after replacing the cable,but it still sticks.In time if not fixed the cable will stretch and break again.

I'll have to try what your saying.
To remove the center vent,I'm going to lube the blend door,is it needed to remove the radio?Is there any screws that need to come off?
 

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I got new cable on and I sprayed the door that slams shut with silicone spray.It helped but it's not a repair,door will stick again.
The rubber seal does get sticky,was so in my case,and then door gets stuck if left for over an hour.
I find that leaving vent knob one click from full left or right will keep it from sticking and you can move it to other spots when needed.
If you do go to full right or left it doesn't seem to stick if you only keep it at that position for a few minutes.
Other than that I see no fix,unless you clean out where you can't reach and replace the door you can't reach or tear the dash apart.
I accept it as a one of the weak points of a Focus.
 

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Alright guys, everyone here is dead on accurate about the rubber seal on the blend door sticking. Wish I would have known about the silicon spray trick before I did the job, that woulda been nice!

This problem was driving me crazy for almost 2 years. I tried every jerry-rig method I could think of for a temp fix, but I decided it was time to do it for real this time. Pretty big deal considering I live in the midwest where defrost in the winter is a lifesaver.

The only real fix for this is to remove the entire heater core housing and replace. It is a hell of a job - removing the dash, crossbar member and all associated wiring harnesses. But I am an amateur and was able to handle the mechanics just fine; it just took a while. Took me a solid 3 days to get the job done. Get the Haynes manual - it is a must have.

What I did was practice ripping one of these cars apart at a pick & pull junkyard - that way you get to screw that car up instead of your own so you can learn what works and what doesn't. Pick a decent looking car, the idea being if it looks nice, it probably has lower miles on it, increasing the odds of getting a fully operable heater core housing. I lucked out in that area.

The part is I think in the neighborhood of $450 new but I got it at the junkyard for $60. You'll be able to inspect the blend door operation before you take it home obviously so make sure that checks out.

This job requires you to unhook your A/C hoses which will leak freon which is why its a good idea to vaccuum it out or have a shop do it. Reinstall heater core and have a shop recharge A/C unless you can do it yourself.

I'm almost positive this problem is created by excessive heat melting the little rubber flap that seals the blend door. Obviously it is designed to withstand the heat coming from your HVAC system, and I'm not sure of exact temps here, but I park outside usually and I'd notice after a couple days of inactivity things in my car (stickers, plastic, etc.) would be noticeably melted and I think that's what has happened here. Just speculation. I got one of those sun shades to keep the temp down in direct sunlight. Wish I had time and motivation for a full write up. In the mean time, good luck guys.

-Brad
 

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mine started doing the same thing about 2 years ago, 2007 zx3, at first it would just get stuck on defrost and i could put a little force and it would free up until one day the cable just snapped... thinking it was just the cable i went to the junkyard and pulled 4 extra cables out of earlier model foci which have the same cable and connections and same blend door and door track, i also went ahead and got another track and 2 or 3 extra switches of each kind, i replaced the broken cable (hint: don't move any of the ac control switches after you disconnect them... it makes it slightly difficult to reattach them) and that fixed the nothing at all problem but the door still sticks to this day. i've thought that you could buy some AC cleaning foam that you inject into the blend doors and it fills up with soapy foam and drains out of the drain plug, my friend uses it at toyota occasionally, but i have yet to actually do anything about it, i rarely use my AC. Might try spraying a little silicon spray in there but i think a more permanent fix could be cleaning the entire blend door with the AC cleaning foam, however it may or may not work with the deteriorating rubber seals... only one way to find out for sure. has anyone tried cleaning the blend doors with AC system cleaning foam?
 

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I discovered a few things that may help with sticky cables,it's just a weak spot in Focus's with high milage,even if you replace cables they may still stick.Mine did and this seemed to help.If you force it cables will stretch again then you have to replace cables.

If it's cold in morning,you used air the day before and your knobs are set to cool,let car warm up before moving knobs to full right or left.Just add enough warm air to loosen up that foam seal that seems to stick if left at full left for coldest air or for just vents in dash
Opposite if used heat day before.

If I don't forget I don't leave knobs full left or right when I park car or shut down for that day.

That foam-seal when door shuts to control air flow seems to stick when it's very hot or cold in cabin.Let car cool or warm up before moving knobs to extreme settings.The temp knob can get sticky or stiff also.If car warms or or cools down it will move easier also.
 

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I can hardly wait to get mine fixed. I forced it and now I only get air out of the dash and floor vents, No defrost vents at all. Since I live in Ohio I need to get this fixed before the snow flies. Ford dealer probably wants $500 to fix this problem.
I would try fixing it myself, but I live in an apartment and since it's my only car, I don't want to break anything else in the process or be stuck trying to reassemble the dash.
 

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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.
My solution to prevent sticking in my '07 is quite simple and effective. The vent blend dial range is from 8 o'clock thru 4 o'clock position. If you don't want it to stick, just quit moving it to the stops at the 8 and 4 o'clock positions. My dial is never moved to the lower hemisphere...beyond 9 and 3 o'clock, so the vent dial no longer sticks. As for HVAC system performance, I have no need or desire to use the full defrost or full upper vent positions. A blend position suits me fine.
 
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