Total HVAC box replacement, not a fun ordeal!

[danmoochie]

Posted parts of this prior, but after 3 weeks and 3 complete dash removals, the final fix to what I thought was just a blend door actuator ended up being a complete HVAC box replacement, tearing the truck down to the firewall.

Started with a clicking in the dash behind the driver side vent. It got worse over time and the dealer finally agreed to replace the blend door actuator. Week one, they tore the dash apart and decide to replace both actuators, driver and passenger, good move since the dash was out. Got the truck back after a week, only to find out the AC only came out the foot wells, no vent or defrost.

Week two, they decided Ford sent bad actuators, and tore the dash apart and replaced them both again, only to find out that did not work!

On to week three, they ordered a complete HVAC unit, tore the truck apart to the firewall and replaced everything! I got the tuck back the other day, and it seems to be working as designed, finally.

I am a little unhappy with some of the trim pieces looking worn at the edges, and will probably have them replace them at some point, but for now I want to make sure everything is work and stays working.

This is not the first issue with my truck, already had the front driver CV joint and axle replaced, and we all had several recalls, and a few other minor issues.

I love the truck, my second one, had a 24 RR, that I traded in due to other issues. Just hard to swallow two trucks, and both have issues that in this day and age you just should not have to deal with on a new vehicle.

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[Muffin1]

Can't believe this is still a issue. I had this done on my 5th gen 2019 with the Ext warranty picking up the tab, thought Ford would have learned a lesson and had this redesigned, geez.

 

[danmoochie]

Can't believe this is still a issue. I had this done on my 5th gen 2019 with the Ext warranty picking up the tab, thought Ford would have learned a lesson and had this redesigned, geez.

Exactly..... but what I thought was an actuator I truly think was a bad box with warped doors or whatever, just a shame they can't build something so important to better specs in this day and age, more so with years of issues related to this.

 

[Jason B]

Can't believe this is still a issue. I had this done on my 5th gen 2019 with the Ext warranty picking up the tab, thought Ford would have learned a lesson and had this redesigned, geez.

They did, as not many 2020 - 2023 had this issue. But I assume 6G is another design that may need tweaking.

 

[danmoochie]

They did, as not many 2020 - 2023 had this issue. But I assume 6G is another design that may need tweaking.

I have posted several times as this went along and did not see or get any replies of others with the issue, so it may very well be isolated, and I just got luck LOL.

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