End all be all actuator replacement thread (clicking sound, part numbers, video install)

[SrsBsns]

Sorry, I misunderstood you.

Like I said, the ones I listed work in my car so in my opinion what the other fellow wrote does not make sense...I’m only posting my experience which did not come from a website, it came from actually putting the specific parts with these specific numbers in my car.

Yeah, I think you have it the right way.

I purchased two of the Dorman 604-400's and installed one on the driver's side and one on the passenger side since I thought they were the same part on both sides. The one on the passenger side is the one that's making noise now, so I'm replacing it with the 604-251. If that fixes my problem, it means that you've got your numbers in the right spot.

Thanks.

 

[danbfree]

Sorry, I misunderstood you.

Like I said, the ones I listed work in my car so in my opinion what the other fellow wrote does not make sense...I’m only posting my experience which did not come from a website, it came from actually putting the specific parts with these specific numbers in my car.

Yeah, I think you have it the right way.

I purchased two of the Dorman 604-400's and installed one on the driver's side and one on the passenger side since I thought they were the same part on both sides. The one on the passenger side is the one that's making noise now, so I'm replacing it with the 604-251. If that fixes my problem, it means that you've got your numbers in the right spot.

Thanks.

Apologies guys, I may have totally had the driver and passenger side backwards based on the actual diagram... Jeff can you confirm which side is driver/passenger in this pic? I feel REALLY bad I may have had that backwards! I thought 21 was clearly passenger side but I may have been a total idiot!

 

[jeff]

Apologies guys, I may have totally had the driver and passenger side backwards based on the actual diagram... Jeff can you confirm which side is driver/passenger in this pic? I feel REALLY bad I may have had that backwards! I thought 21 was clearly passenger side but I may have been a total idiot!

View attachment 27410

No worries bro. From that picture I surmise that part #22 looks like a cabin filter and if that's the case then part #19 is the passenger side actuator since it's close to the cabin filter which is on the passenger's side. By the process of elimination that means #21 is the driver's side.

 

[danbfree]

No worries bro. From that picture I surmise that part #22 looks like a cabin filter and if that's the case then part #19 is the passenger side actuator since it's close to the cabin filter which is on the passenger's side. By the process of elimination that means #21 is the driver's side.

Thanks buddy! I have updated my post, as I clearly had each side backwards... but at least my original post still clarifies the cross reference numbers, so I hope that helps some people out!

 

[danbfree]

Yeah, I think you have it the right way.

I purchased two of the Dorman 604-400's and installed one on the driver's side and one on the passenger side since I thought they were the same part on both sides. The one on the passenger side is the one that's making noise now, so I'm replacing it with the 604-251. If that fixes my problem, it means that you've got your numbers in the right spot.

Thanks.

I'm SO sorry I had the driver and passenger side backwards, so I fixed that... it does still clarify all the other cross reference issues Jeff had in his original post, I just literally had the words "passenger" and "driver" reversed.

 

[SrsBsns]

I'm SO sorry I had the driver and passenger side backwards, so I fixed that... it does still clarify all the other cross reference issues Jeff had in his original post, I just literally had the words "passenger" and "driver" reversed.

No worries at all, I was just referencing this thread before buying a part and when I saw the opposite numbers, I hoped to find clarity and I think we all did. That's why I love this forum. Both you and Jeff have helped me out a lot as I've learned more about this car and modded more and more.

 

[danbfree]

No worries at all, I was just referencing this thread before buying a part and when I saw the opposite numbers, I hoped to find clarity and I think we all did. That's why I love this forum. Both you and Jeff have helped me out a lot as I've learned more about this car and modded more and more.

PHEW! SO glad we were both available to reply and get my mistake fixed before you buy the wrong side... But I know I'd be torn on which brand to try. Supposedly the Dorman design is better but has the shortest warranty and has complaints too, I'm thinking for the same price I'd take the Standard one... with a 3 year warranty, it looks to be very similar design as Motorcraft OEM but hopefully better quality with the longer warranty, I think I'd start there, but dang, hard to tell!

 

[SrsBsns]

Ok... So...

Installed the Dorman 604-251 on the passenger side over the weekend.

Both pieces... the 604-251 and the 604-400 basically look identical.

I removed the 604-400 that I had installed on the pass side and when I unscrewed it, the white gear was no longer fully connected to the actuator. It popped right back in, but that was strange.

I installed the 604-251 and it slid in and fit fine, but my HVAC still isn't switching vents.

I have the 604-400 installed on the driver's side and the 604-251 on the passenger side. I'm not getting any noises or clicks, but the fans only blow out of the face vents.

Any ideas where to start troubleshooting?

 

[danbfree]

Ok... So...

Installed the Dorman 604-251 on the passenger side over the weekend.

Both pieces... the 604-251 and the 604-400 basically look identical.

I removed the 604-400 that I had installed on the pass side and when I unscrewed it, the white gear was no longer fully connected to the actuator. It popped right back in, but that was strange.

I installed the 604-251 and it slid in and fit fine, but my HVAC still isn't switching vents.

I have the 604-400 installed on the driver's side and the 604-251 on the passenger side. I'm not getting any noises or clicks, but the fans only blow out of the face vents.

Any ideas where to start troubleshooting?

Flash to another tune and back or pull the fuse to the HVAC system to see if it resets?

 

[SrsBsns]

Flash to another tune and back or pull the fuse to the HVAC system to see if it resets?

I hadn't even thought about the tune. I'll flash back to stock to see if that helps and then can flash back to the E30 later.

 

[bhmax]

Thanks for the info! Just took care of my driver side actuator. It went bad in my 2016 at about 35k mi. Shown is my stock one with the broken gear, and a Standard Motor Products version. My untrained eyes can’t really tell a difference.

 

[jeff]

Today I replaced my driver's side actuator. Just a few thoughts on this horrible job:

* As stated above the Motorcraft YH-1896 is the one you want
* It took me 13 minutes to remove and 18 more minutes to install so that's 31 minutes start to finish not including tool cleanup
* My neck hurts now...I am 47 years old...up to this point my body will still tolerate being folded into a pretzel for these types of jobs...
* It works perfectly after testing
* It first broke under warranty at 6,000 miles, now at 37,000 miles this is the second replacement (passenger side broke too, once, about a year ago)
* Simply remove x3 T25 screws from the steering wheel column, raise the steering wheel, then remove x2 T20 screws to free actuator, unplug the actuator, reverse
* If the gears aren't lined up the actuator won't go in...if this happens just spin the little wheel gear to the right of the actuator (you'll see it, it has teeth) a bit until the actuator engages
* Thumb wrench works great on the bottom T20
* For the top T20 I recommend a good ratchet with lots of teeth otherwise it will take longer
* I recommend taping your T20 bit otherwise if it falls out you're gonna wish you were never born
* To unplug the actuator you have to first raise the little red tab, then depress the black tab, then pull free....sounds worse than it is, it can be done with one hand with patience
* Take breaks and stretch your neck while working the screws in/out to help avoid pulling a muscle (trust me)
* Some have pulled their driver's seat out to make more room but I was able to leave it installed
* Pictured below are a variety of tools/extensions I used
* You might mark the bad one otherwise you could get confused as to which is the new and which is the old

With the right tools and a bit of patience this isn't really that bad. But Ford should replace these free - parts and labor. This is ridiculous. If I recall people are paying >$300 for this repair at the dealer. I keep one on the shelf in my garage since they break so often.

Here's the best video I found to help you:

View: https://www.youtube.com/watch?v=uuENktnNelc&ab_channel=AutoRepairGuys

 

[Remi]

So what I'm understanding is that Dorman has the better quality product, but with shorter warranty. And it's still known to fail.
Motorcraft has the longer warranty but shorter lifespan???

 

[gtx3076]

I just replaced the passenger side and now my driver side went out. What an annoying repair. Such a stupid thing to have to keep replacing.

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[XR650R]

I just replaced the passenger side and now my driver side went out. What an annoying repair. Such a stupid thing to have to keep replacing.

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You're in luck. Jeff also did a video on replacing the other one, and it's easier.

View: https://www.youtube.com/watch?v=eAu9J2zFuz0&t=3s

 

[gtx3076]

You're in luck. Jeff also did a video on replacing the other one, and it's easier.

View: https://www.youtube.com/watch?v=eAu9J2zFuz0&t=3s

I already did the passenger side, it's the driver's side...

 

[XR650R]

Oh.

 

[faust]

So what I'm understanding is that Dorman has the better quality product, but with shorter warranty. And it's still known to fail.
Motorcraft has the longer warranty but shorter lifespan?

From what I've read, although the Dorman seems like it should last longer, people are having better results with the updated Motorcraft part.

 

[gtx3076]

I just did the driver side. Definitely harder to get to but not the worst thing I've ever had to do. Maybe took me 15 minutes. A decent bit ratchet is handy. It was likely not the original since there was only one screw holding it in.

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[draxxus131]

Just came across a specific item on thingiverse.com. The item noticed was a 3d gear for the mk7 fiesta blend door actuator, the main gear cog. Would this be of good use to the community or are some cars having issues with the smaller gear decaying?

https://www.thingiverse.com/thing:4512624

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