Feel like you should have used the metallic tape to hold the cardboard covers in place because thatbtape is for high heat and the plastic duct tape may get warm and let go
People like to dis the old Focus but I’ve had mine for 11 years with factory parts and this is the biggest problem I’ve had with it. It’s been a good car.
Before you do surgery on your car. Remove selector knob and place in on linkage stud under dash. Run the car to temp and run the heater (I drove mine for about 15 min). (windows open when the sun is down during summer) If you are lucky, the door isn't fully melted and heating it up will allow you to move it out of min/max position, cranking on knob under dash. Then can place knob back on panel when freed.
Great instructions and video. I appreciate you gave credit to others that have also posted on this repair in the past. Your more recent effort is the most direct and very well recorded considering what a tough spot it is. We really like our Focus (150,000+ miles) but this is obviously a design flaw with the flap material.
We fixed ours just like this, but I used a plastic welder to put the original plastic doors we cut out, back on. I also didn’t cut the doors quite as big, just enough to get my hands on the flapper to apply the aluminum tape on the bottom.We also didn’t cut out the small top pieces, just the bottom.
Thanks Ron!!!. My stepsons car had a issue where we couldn't change the temperature. I used your instructions to get into the box and was able to get that door working again. He's had some stiction on the deflector like you showed so I did the tin foil tape like you showed. It's all working great now, he has heat and just in time. The high is 20 degrees today. Great instructions. John in Minnesota
Thanks for posting this. About to go through it with my Focus. It was sticking at both ends of it's travel, and now just doesn't work at all. I will assume that is because I broke one of those cables, and will need to replace it. As some others have said, this is the biggest real problem I've had with the car. Some worn out parts, but that is life with an older car. It runs great, handles great, stops great. AC blows ice cold, just need to fix up that flapper door.
Thank you so much for this, it's been difficult to find a good guide on how to fix this problem. Out of curiosity, how has this repair been treating you since? Still working well?
Holy crap dude, I'm so happy I found this video, your footage on actually cutting the plastic is really going to help me when I do mine, too badi have to get another control cable 😅 you're awesome man
man that was a money saver, car runs great still just little stuff like the flapper that was annoying. I used adhesive felt that goes around a charcoal grill lid. Works like a new one, also used the tape you did to cover the cutout with card board. Covered the card board in that tape to keep moisture from destroying it over time. Thanks !!
Thanks for the video. I ended up having to do this repair as well. However, I used a butane torch to heat a box-cutter blade (and it cut through like butter). I also didn't bother cleaning the top side rubber off, because the surfaces were sttill clean (like brand new)...my problem was entirely at the bottom.
That's helpful - I was figuring to use my dremel and wasn't sure how to do it because I just got it not long ago and don't know how to make a straight in line cut. I might try your way - I don't have the tool Ron has.
@@mortonbortell3755 No prob. Just make sure you use a good sharp knife...I had to constantly straighten my box cutter blade because it was pretty dull.
@@KardiFan2000 The dremel with a straight cutting bit worked really well. Have to go slow and let the bit get warm, then just go kinda slow. Scored a shallow line first and then went deeper - otherwise it was all over the place. Made the openings a little bit smaller than a single receptable metal outlet cover and taped them on with the metal tape used for the flap bottom and sides. Works much better now. If I have to do it again down the road, I'll make a bigger cut because it was really hard to do the tape well.
Great video. I found out as I was watching this with mine apart and no cutting as long as you don't turn the knob all the way down to the left or right it doesn't stick just don't put it all the way on defrost or all the way on dash so it can't touch the other sticky stuff. And it still switches like it should and blows like it should but it doesn't let the actuator doors touch the sticky stuff so it doesn't stick.
That was a great vid. Have the exact same issue with my ‘07 Focus. BUT I also have a problem with the temperature dial. The flapper for the temperature sticks as well. Have you encountered an issue with that?
Recently bought an 05 Focus at auction, stuck on defrost and the damper switch was broken, replaced that this morning and found out why that was broken. Ron, what is that foil tape you used, couldn't tell just what it is from the video.
Hey all, I've had this problem for quite a while. WD40 worked for a bit but not exactly a fix. I am going to do this this weekend. My main question is ..why not cut it all the way through the center part? Basically 1 big rectangle instead of each side.
Getting ready to do this for a friend's car. How's this repair holding up? Was that gorilla tape you used at the end there with the cardboard panels? We live in the desert so I'm not SUPER concerned about humidity messing with the tape, but I want to be sure I'm not going back in there in 6 months to reseal it, you know? Got a reputation to keep up!
Update! Got it knocked out in less than 2 hours including time inside to not die of heat stroke. Saved my friend a LOT of money and made my life way easier. Thanks!
I’m doing this with my daughters car now. Does the door actually touch the top? Is the top foil tape needed? And can I just cut the middle section out too or is it needed for structure? Thanks! B
Like with a lot of stuff on amazon, models tend to change, I went back and looked at my order and it came up with this, amzn.to/3RTcJ6f I am assuming its an upgrade? hope this helps.
@@channelron3593 stupid design if you ask me.. Why put a rubber seal that could melt into a sticky glue on a flap that it’s essential to open and close.
@@CyberWolfVR With cars, sometimes things are fine for decades then some engineer moves something an inch, and we don't know it was a problem for another decade. {or supplier changed, or supplier's supplier changed, or supplier's supplier's supplier was victim of fraud, etc... ;) In hindsight... yes, having possibly decomposing parts in close proximity to the heater core, and hardly accessable for repair/replace wasn't ideal. In their defense, this little economy car sure heats up nicely in the winter.
Feel like you should have used the metallic tape to hold the cardboard covers in place because thatbtape is for high heat and the plastic duct tape may get warm and let go
People like to dis the old Focus but I’ve had mine for 11 years with factory parts and this is the biggest problem I’ve had with it. It’s been a good car.
Yep they are bulletproof
Before you do surgery on your car. Remove selector knob and place in on linkage stud under dash. Run the car to temp and run the heater (I drove mine for about 15 min). (windows open when the sun is down during summer) If you are lucky, the door isn't fully melted and heating it up will allow you to move it out of min/max position, cranking on knob under dash. Then can place knob back on panel when freed.
Great instructions and video. I appreciate you gave credit to others that have also posted on this repair in the past. Your more recent effort is the most direct and very well recorded considering what a tough spot it is. We really like our Focus (150,000+ miles) but this is obviously a design flaw with the flap material.
You are welcome!
We fixed ours just like this, but I used a plastic welder to put the original plastic doors we cut out, back on. I also didn’t cut the doors quite as big, just enough to get my hands on the flapper to apply the aluminum tape on the bottom.We also didn’t cut out the small top pieces, just the bottom.
Nice let me know how it works out.
Thanks Ron!!!. My stepsons car had a issue where we couldn't change the temperature. I used your instructions to get into the box and was able to get that door working again. He's had some stiction on the deflector like you showed so I did the tin foil tape like you showed. It's all working great now, he has heat and just in time. The high is 20 degrees today. Great instructions.
John in Minnesota
Glad it helped
Thanks for posting this. About to go through it with my Focus. It was sticking at both ends of it's travel, and now just doesn't work at all. I will assume that is because I broke one of those cables, and will need to replace it.
As some others have said, this is the biggest real problem I've had with the car. Some worn out parts, but that is life with an older car. It runs great, handles great, stops great. AC blows ice cold, just need to fix up that flapper door.
Glad it helped!
Thank you so much for this, it's been difficult to find a good guide on how to fix this problem. Out of curiosity, how has this repair been treating you since? Still working well?
starting to hang up a bit but still working
Holy crap dude, I'm so happy I found this video, your footage on actually cutting the plastic is really going to help me when I do mine, too badi have to get another control cable 😅 you're awesome man
Glad I could help! I gave this car to my son and it is still working fine.
Thanks mine has the same issue. Broke the cable trying to force it. Replaced the cable and now I’ll do this to unstick it.
man that was a money saver, car runs great still just little stuff like the flapper that was annoying. I used adhesive felt that goes around a charcoal grill lid. Works like a new one, also used the tape you did to cover the cutout with card board. Covered the card board in that tape to keep moisture from destroying it over time. Thanks !!
Thank you!
Glad I found your video. I thought I would have to take the whole dash apart.
❤Your instructions…. Awesome job and thank you.
You are so welcome!
Thanks for the video. I ended up having to do this repair as well. However, I used a butane torch to heat a box-cutter blade (and it cut through like butter). I also didn't bother cleaning the top side rubber off, because the surfaces were sttill clean (like brand new)...my problem was entirely at the bottom.
Nice work! whatever works! Thanks for supporting my channel.
That's helpful - I was figuring to use my dremel and wasn't sure how to do it because I just got it not long ago and don't know how to make a straight in line cut. I might try your way - I don't have the tool Ron has.
@@mortonbortell3755 No prob. Just make sure you use a good sharp knife...I had to constantly straighten my box cutter blade because it was pretty dull.
@@KardiFan2000 The dremel with a straight cutting bit worked really well. Have to go slow and let the bit get warm, then just go kinda slow. Scored a shallow line first and then went deeper - otherwise it was all over the place. Made the openings a little bit smaller than a single receptable metal outlet cover and taped them on with the metal tape used for the flap bottom and sides. Works much better now. If I have to do it again down the road, I'll make a bigger cut because it was really hard to do the tape well.
@@mortonbortell3755 Nice! Glad it worked out for you.
Great video. I found out as I was watching this with mine apart and no cutting as long as you don't turn the knob all the way down to the left or right it doesn't stick just don't put it all the way on defrost or all the way on dash so it can't touch the other sticky stuff. And it still switches like it should and blows like it should but it doesn't let the actuator doors touch the sticky stuff so it doesn't stick.
Ya a bad design on ford part but should get you by,
.....You don't have a wife, then!
I don’t like duck tape for long term use. I think the foils tape would’ve been a better choice. What do you think?
That was a great vid. Have the exact same issue with my ‘07 Focus. BUT I also have a problem with the temperature dial. The flapper for the temperature sticks as well. Have you encountered an issue with that?
If anyone needs to do this, use a dremel with a drill bit attachment and you can easily and precisely cut the hole hassle free.
Just cut mine apart. Gonna take out top also..must line up actuator ..spray lube on all moving parts
Recently bought an 05 Focus at auction, stuck on defrost and the damper switch was broken, replaced that this morning and found out why that was broken. Ron, what is that foil tape you used, couldn't tell just what it is from the video.
I used it to help seal the damper and to cover up the glue a bit because it was still a bit sticky.
What was the glue from bud?
Hey all, I've had this problem for quite a while. WD40 worked for a bit but not exactly a fix. I am going to do this this weekend. My main question is ..why not cut it all the way through the center part? Basically 1 big rectangle instead of each side.
Good ? I am not sure why I did not maybe I was worried about the structure.
Did you cut through the middle and make one large rectangle? If so, did that cause any issues?
Getting ready to do this for a friend's car. How's this repair holding up? Was that gorilla tape you used at the end there with the cardboard panels? We live in the desert so I'm not SUPER concerned about humidity messing with the tape, but I want to be sure I'm not going back in there in 6 months to reseal it, you know? Got a reputation to keep up!
Update! Got it knocked out in less than 2 hours including time inside to not die of heat stroke. Saved my friend a LOT of money and made my life way easier. Thanks!
I’m doing this with my daughters car now. Does the door actually touch the top? Is the top foil tape needed? And can I just cut the middle section out too or is it needed for structure? Thanks! B
Yes and yes, their was glue all around it so I put tape to help it from not sticking.
Broke original control broke replacement. Now I can repair right way .
i wonder if for ever had a cheap TBS fix for this
Nope. Ford will tell you to replace the whole HVAC box.
Question… do your vents constantly blow air even if the blower is off? Mine does people tell me this is normal and i just do not believe that
Not sure?
@@channelron3593 am i sure about what? That my car should not constantly be blowing hot air with my blower turned off? Yeah pretty sure
Do you absolutely have to cover it back up with something? Like cardboard?
I would just so you get full air pressure.
I have a focus 1.6 TDCI 2009 and unfortunately, I can’t get to it at all behind the stereo. My car dashboard looks different to yours? 🤷♂️
bummer, ya its a problem that they had with them.
Where you bought your Touchscreen radio? What brand it is?
Like with a lot of stuff on amazon, models tend to change, I went back and looked at my order and it came up with this, amzn.to/3RTcJ6f I am assuming its an upgrade? hope this helps.
Thanks abunch
My temperature door is the one sticking. Is that door accessible from here?
No this is the direction, vent feet and defrost
@@channelron3593 ...I do know this. So the temperature door is not accessible through here was my question.
Ron total time for job?
With out filming,, 2 hrs at the most
Why is there "glue" there to begin with?
I think it is the old rubber that has melted over the years.
@@channelron3593 Ah ok, that makes sense.
@@channelron3593 stupid design if you ask me.. Why put a rubber seal that could melt into a sticky glue on a flap that it’s essential to open and close.
@@CyberWolfVR With cars, sometimes things are fine for decades then some engineer moves something an inch, and we don't know it was a problem for another decade. {or supplier changed, or supplier's supplier changed, or supplier's supplier's supplier was victim of fraud, etc... ;)
In hindsight... yes, having possibly decomposing parts in close proximity to the heater core, and hardly accessable for repair/replace wasn't ideal. In their defense, this little economy car sure heats up nicely in the winter.