I haven't seen one of these in awhile so I decided I better make a video of the fix. So if you have a windstar that just makes a clicking noise in the dash when you go to change the heater temp hot to cold etc this is your problem. Early windstars the doors would stick and break the actuator but the newer ones 2000 forward don't seem to have that issue. Either way I show you how to change the faulty actuator out and check the door for free movement. I hope this help families out there on a budget.

 

Good video !
Will help a lot of folks with Windstars.
Thanks.

 

Yep there are still allot of them out there, people love to hang onto these and fix them as they go.

 

If your problem is the blend door and not the actuator, then this may be helpful. My problem was that the plastic blend door in the HVAC plenum or duct was broken. There is a simple fix using a nail that you can find on the internet if the door is not badly damaged, but mine was badly damaged. The actual shaft that the motor slides into was busted. This is a very expensive repair at the dealer ($1,000 or more!) as they have to disconnect the cooling system (heater core) and the AC system (evaporator) and completely remove the HVAC duct from the van to replace the door. There was no way I was going that route. I found a better solution which was:

http://www.heatertreater.net/

This website sells an improved blend door with a metal shaft that will not wear out like the OEM plastic one did. I think the part was around $100 and I bought it off of eBay from them for a little less than just getting it from their website. They have videos showing how to repair various blend doors and it was extremely helpful.

Hope this helps somebody!