2004 Freestar Heater Issue
 

My '04 Freestar heat is not working set to the normal heating settings. I can only get heat when control is set to "max a/c" with temperatureknob set tored. This does not work well because my windows keep fogging and when I change the control to defog, no heat. No heat on any setting except max a/c. (note: thermostat/gasket replaced, but did not fix issue).

Anyone out there that can point me in the right direction?

Thanks and Happy New Year!

RE: 2004 Freestar Heater Issue
 

You probably have a problem with the BLEND door in the dash. It's probably hung up or broken. I can hear mine groaning
occasionally when changing from one position to another.

RE: 2004 Freestar Heater Issue
 

Thanks so much for responding. Any chance you know how to fix it? My husband is pretty good at fixing cars, though his expertise is in Volvo 240's. With the Volvo 240's he knows them inside and out, but with the van, he can fix it if he's given little more detail of how to fix the problem.

RE: 2004 Freestar Heater Issue
 

Not sure myself, but I'm sure it's a real bear to get to. I haven't looked at mine yet. Was going to see if I could get some silicone sprayed onto the hinge point(s) of mine. I'll probably wait till the weather changes a little here in the snowbelt...

RE: 2004 Freestar Heater Issue
 

I have a similar problem, although not your exact problem. Regardless of what setting I have my heat set to, all my windows fog up if the temp is below freezing outside. I live in Colorado, and it happens here - but it happens much, much worse in places like Iowa where the air is more humid. I have my defrost turned on obviously, and it still happens. I had to take it to the dealership NINE times!! Each time they say they can't reproduce it - during the day, the sun is bright enough or it's warm enough outside to make it appear fine. I've had it at two dealerships for this very issue, and the second finally replaced the heater core for me at no charge. That didn't do a damn thing. The problem mostly occurs at night, the colder it is, the more fog I get. I have to have the blower on the dash and in the rear set to 4 just so I'm able to see through holes cleared in the windshield.

My thinking is that the little flap that controls whether I'm getting outside air or inside air is defective. Anybody else seen this?

RE: 2004 Freestar Heater Issue
 

If anyone else can point me in the right direction on this, I'm really looking for some direction. I know they'll rake me at the dealer and may not even fix it.

RE: 2004 Freestar Heater Issue
 

From what I found out from a friends Freestar it is a vey labour intensive job.
She was quoted $1800 and maybe more so she trades thevan and got another Ford van.
Her van had about 150.000 miles on it.
Don't know if this is of any help but it might help you to decide.

RE: 2004 Freestar Heater Issue
 

Your problem most sounds liek the symptom "Insufficient, erratic, or no heat" in the symptoms chart in the 2005 Ford Freestar Shop Manual. Possible sorunces listed are low engine coolant level, engine overheating, plugged or partially plugged heater core, temperature blend door is binding or stuck, temperature blend door actuator, heater hose is kinked or binding.