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Discussion Starter #1
Air only coming out defrost vents. Blend door moves freely by hand but actuator is not working. Replaced actuator and tried two different head units...no difference. What other steps can I take? The diagnostic error code shows "blend door actuator not working" message. HELP!
 

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It sounds as thought you have 2 problems. 1: Vacuum leak causing no vacuum to the vacuum motor controlling the floor/defrost door. Check for a vacuum line in the engine bay laying across something hot or accidentally disconnected. Check for hose pulled off vacuum reservoir under right front wheel wheel well. 2: A problem in the wiring for the blend door actuator.
Don't know if this is the EATC system on your expy but here is some information.

Attached also is a pdf with the service manual blend door pin point test sequence.

No vacuum to the A/C control.
A/C control leaks vacuum.
Kinked/pinched vacuum hose.
Vacuum control motor.
A/C vacuum check valve.
A/C vacuum reservoir tank and bracket
Vacuum actuator arm not connected to the door crank

Electronic Automatic Temperature Control Module Self-Test:

The EATC module self-test will not detect concerns associated with data link messages like engine coolant temperature or vehicle speed signals. A NGS tester must be used to retrieve these concerns.

The EATC module self-test will detect concerns in the system control functions and will display hard diagnostic trouble codes (DTC) in addition to intermittent diagnostic trouble codes for concerns that occur during system operation. The vehicle interior temperature should be between 4°-32°C (40-90°F) when performing the self-test. If the temperatures are not within the specified ranges, false in-car temperature sensor DTCs will be displayed.

The self-test can be initiated at any time. Normal operation of the system stops when the self-test is activated.
To enter the self-test, press the OFF and FLOOR buttons simultaneously and then press the AUTOMATIC button within two seconds. The display will show a pulse tracer going around the center of the display window. The test may run as long as 30 seconds. Record all DTCs displayed.

If any DTCs appear during the self-test, follow the diagnostics procedure given under ACTION for each DTC given.
If a condition exists but no DTCs appear during the self-test, refer to the Symptom Chart Condition: The EATC System Is Inoperative, Intermittent or Improper Operation.

To exit self-test and retain all intermittent DTCs, push the blue (cooler) button. The control will exit self-test, retain all intermittent diagnostic trouble codes and then turn OFF (display blank).

To exit self-test and clear all diagnostic trouble codes, press the DEFROST button. The vacuum fluorescent display window will show 888 and all function symbols for one second. Then, the EATC control assembly will turn OFF (display blank) and all DTCs will be cleared.

Always exit the self-test before powering the system down (system turned OFF).
Intermittent DTCs will be deleted after 80 ignition switch ON cycles after the intermittent condition occurs.
 

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Discussion Starter #3
Thanks so much for the detailed troubleshooting ideas. I've got some work ahead of me! Appreciated!
 

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Thanks so much for the detailed troubleshooting ideas. I've got some work ahead of me! Appreciated!
you're very welcome. If you need any connector pin-outs or other service manual type information I'll try to get it for you.
 

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Did you consider the blower motor? A couple of years ago I had to replace it because the fan would not shut off or change speed. Keep us posted...
 

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1997 Explorer XLT 6cyl

It sounds as thought you have 2 problems. 1: Vacuum leak causing no vacuum to the vacuum motor controlling the floor/defrost door. Check for a vacuum line in the engine bay laying across something hot or accidentally disconnected. Check for hose pulled off vacuum reservoir under right front wheel wheel well. 2: A problem in the wiring for the blend door actuator.
Don't know if this is the EATC system on your expy but here is some information.

Attached also is a pdf with the service manual blend door pin point test sequence.

No vacuum to the A/C control.
A/C control leaks vacuum.
Kinked/pinched vacuum hose.
Vacuum control motor.
A/C vacuum check valve.
A/C vacuum reservoir tank and bracket
Vacuum actuator arm not connected to the door crank

Electronic Automatic Temperature Control Module Self-Test:

The EATC module self-test will not detect concerns associated with data link messages like engine coolant temperature or vehicle speed signals. A NGS tester must be used to retrieve these concerns.

The EATC module self-test will detect concerns in the system control functions and will display hard diagnostic trouble codes (DTC) in addition to intermittent diagnostic trouble codes for concerns that occur during system operation. The vehicle interior temperature should be between 4°-32°C (40-90°F) when performing the self-test. If the temperatures are not within the specified ranges, false in-car temperature sensor DTCs will be displayed.

The self-test can be initiated at any time. Normal operation of the system stops when the self-test is activated.
To enter the self-test, press the OFF and FLOOR buttons simultaneously and then press the AUTOMATIC button within two seconds. The display will show a pulse tracer going around the center of the display window. The test may run as long as 30 seconds. Record all DTCs displayed.

If any DTCs appear during the self-test, follow the diagnostics procedure given under ACTION for each DTC given.
If a condition exists but no DTCs appear during the self-test, refer to the Symptom Chart Condition: The EATC System Is Inoperative, Intermittent or Improper Operation.

To exit self-test and retain all intermittent DTCs, push the blue (cooler) button. The control will exit self-test, retain all intermittent diagnostic trouble codes and then turn OFF (display blank).

To exit self-test and clear all diagnostic trouble codes, press the DEFROST button. The vacuum fluorescent display window will show 888 and all function symbols for one second. Then, the EATC control assembly will turn OFF (display blank) and all DTCs will be cleared.

Always exit the self-test before powering the system down (system turned OFF).
Intermittent DTCs will be deleted after 80 ignition switch ON cycles after the intermittent condition occurs.
Would you happen you have the same connector pin test info that you provided in this post except for the blend door actuator motor on a 1997 Ford Explorer XLT 6cyl?
 

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Would you happen you have the same connector pin test info that you provided in this post except for the blend door actuator motor on a 1997 Ford Explorer XLT 6cyl?
This pdf. is from the 1997 service manual-both manual and eatc systems blend door pinpoint test.
 

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