Tis' the season for people wanting heat from their trucks, and tis' the season that I've noted more and more temperature blend doors breaking in '97-'02 F150s and Expygators. Now, not everyone wants to pay a dealer to replace the door, it is a very labor intensive job, usually calling for 10-12 hours of labor depending on where you shop. So, for the DIY'ers around here, I figure I'd snap a few pictures of a Navigator I replaced the blend door in at work. Unfortunately, since I was on the clock officially, I didn't quite have the time to detail disassembly the way I wanted to. I started on it yesterday evening, when I didn't have my camera, and finished this morning just before lunchtime. So, for your viewing pleasure...
What the...son of a...put that dash back in that truck! Here's the "after," the first picture I took this morning. This shows some of the stuff you'll probably want to take loose to give max room to get in there to the plentum chamber, including the radio antenna lead on the passenger's side, and the three bulkhead connectors on the driver's side.
Bulkhead connectors? Wha? Yeap, that's them, to the right (if you've facing it) of the brake booster. Disconnect the three connectors by loosening the 10mm bolts holding them in place, pry the black lockplate off and squeeze the locking tabs to release them from the firewall.
The aforementioned lockplate for the three bulkhead connectors.
Continued...