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.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.
My 2007 ford focus 2.0 L 4 cly. duratec dohc do not have a place for filter hole seal off with a fine wire screen you can moderfy if you a patient and tools, i just cut a heat pump the correct size laid it on top of the screen where the filter would fit in that hole. broke those hooks off that hold the cowl down in place the hood will also hold the cowl down until i can replace the cowl. i am 77yrs old now eyes gotten dim get tired easy in the last 8 yrs. but i enjoy the guys and girls tell how they modify, and repair their cars, could do pretty well with the vehicles 1960-1992 now just change oil, front wheel brake pads rotters calibers, mafs.door handels,rear shocks on my focus.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.
Here in N C the weather is not extra cold or hot , when my heater/ac / fresh air selectors are stuck, what i have doing is driving for about 5 minuets, will loosen the selectors up they will move freely. from what ever position i left them in over night. but mostly always leave the vent on outside air. could it also be humid that causes them to stick, mine only sticks when car sets over night. sometime i cut on the fan whether it's hot or cold seems to help but have to cut fan off before turning the selector in position i need .stopping or cutting back force of air make makes it easeier to move selectors.2007 ford focus 2.0 duratec.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! [headbang]