torkum

I found this link on a way to repair the broken blend door problem with our trucks. I'm no fan of hacking up factory installed parts but I do know that this is a major fix to do it correct along with cost of paying a dealer or shop to do the repair. Check the site out and watch the two videos and see what you think.
I like the new metal door, just can't get over cutting up the dash inside.

http://heatertreater.net/Ford%20F150%2097-04.htm

KSF150

A guy that works with me just did this last weekend. His door was broken just as they show. The only way he could get heat, was to shift it to heat and then accelerate sharply to help the door. It took less than two hours and it works perfectly now. I would highly recommend it if your door is broken.

torkum

Did he use the kit in the video or just cut the box out and replace the door?

KSF150

He bought the kit from heatertreater. It was a little pricey for just metal door but once you priced it at the dealer for over 600 then it did not seem as bad. Plus the dealer replaced it with the same plastic door.

torkum

Good deal, just wanted to clarify that he used the kit. I think you pay half for the metal door and half for what they know and I that is fare when this can save someone hundreds of $s.
Can't get past cutting the box up

KSF150

Cutting the box was no big deal. When you cut it, simply bolt it back on and then put the tape on it as the video shows. You never see it and it seals great. No problems at all. After doing his, I was tempted to order one for mine since I have 100K on my 02' and figured my time was coming!

jmyers

I agree, it was no big deal. I just did mine today Oct. 13, 2010. I just used a regular door for $25, it took a total of 2 hours. The hardest part was get the door back in the hole. It tells you in the video to put the pin in first, I actually found it easier to put the axle side in first then the top pin of the door. Ford wanted $850 I only spent $25 on door and $9 on metal tape. Thank goodness I did this. The air blows awesome!

nugget68

I used a replacement plastic door from ebay...I seals great when heat it on but when ac is on it is about half an inch from sealing against the heater core...I haven't checked the ac yet since it hasn't been hot since I replaced it but this will probably cause ineffective cooling right?

Other

I've had a new door for almost a year now. Did the procedure in the video, but I can't get the new door in. The pivot at the top is a small piece of plastic that comes out from the wall and is too low for me to fit the top part of the door under it. I feel like I'm going to break something if I try to force it in there.

It would be helpful if anyone can tell me if it is supposed to slide in to the bottom first and then easily slide into the top or if I have to put some good force into it. The bottom is very hard for me to line up as well even after putting my finger in from under.

I have a 1998 F-150 5.4.

Thanks!!!

mrgr8ness

I bought a dorman replacement door off ebay. I had to cut part of the "cup" to get it in there. Was having the same trouble you are. I think I cut a little at a time, till it would go.