2001 - 2003 Mercury Sable Blend Door Repair Kit (part#902-202)

Comments about Dorman - OE Solutions Blend Door Repair Kit:

This product does not fit in 2002 Ford Explorer V6. Product is too small. Easy too pull factory out by going through heater core case under bottom of dash behind console takes two people one to spread the casing and one too monkey the part out. Do not follow online instruction to cut braces and rip unneccasary parts from vehicle. Bottom line is pull the part out before buying the replacement to compare. This one is not the right one for this truck everywhere sells the same part # 902-202 wrong one . One place I did find to have a different one. Still searching hopefully this one will work.

Comments about Dorman - OE Solutions Blend Door Repair Kit:

Throw out the instructions, get on the web and find out how easy it is to pull 3 nuts, 1 bolt and get access to this door. Search heater core replacement or blower case removal. Several videos show you how to pull the case that houses the blower, evaporator and accumulator(receiver-drier). Pull that and the door is right there. All you have to do is remove the blower case with AC Evaporator all as one unit, BE SURE to disconnect the vacuum lines (2 line, 1 connector) under the dash inside the truck, RH side near the kick panel. There's also a nut very near that which needs to be removed. Go out, under the hood, remove the cruise control servo and coolant/washer fluid reservoirs to allow more room. Disconnect the electrical connector for the blower motor and blower resistor, being careful not to break this brittle plastic! Remove the 11mm bolt above the blower motor and two 11mm nuts on studs. Then pull the entire blower case out of the truck, it's a tight fit on the V8 but it will come out, just don't break any sensors on the throttle body. Set the blower case aside. You now have access to the hole in firewall so you can get to the door. Next, drop the glove box and disconnect and remove the actuator to get it out of the way so the door will come out. With a small pry bar, gently pry down on the top of the door as close to the pivot point as you can and door will come free. (If you're super smooth kind of person, you could use a reciprocating saw, just don't puncture your heater core!!!) The next thing to do is break or cut the old door in half so it will pop right out. If you choose not to do this, you can get it out, but it is a little tricky. Now take the new door and cut a small section off the bottom of door to make installation easier(it will still seal inside case). Start cut 3/8" up from the bottom on the outer edge and taper down toward the bottom edge about 2" from the outer edge. Then put in through the firewall hole and into place. This is a little tricky also, but can be done, do not get frustrated. I found that if you put the door through the firewall hole, then through another hole you'll see in there, then tilt the top up toward the top of the case while positioning the bottom of the door shaft/pivot into the lower hole, you'll get it most of the way, then you'll have to pry a little to get the top pivot past a ledge on the top of the case. It will pop right in place. It will take the same gently prying with the pry bar to get pivot hinge to seat in hole. Reinstall actuator, blower case with evaporator and accumulator then recharge the AC system, top off your coolant, re-assemble and reconnect everything the opposite of how you took it out and you are done. Way easier than pulling the dash.[@]

Comments about Dorman - OE Solutions Blend Door Repair Kit:

This product fixed my 97 ranger but it took almost twelve hours to complete the repair. Its cheaper than a dealer repair but very labor intensive.

Comments about Dorman - OE Solutions Blend Door Repair Kit:

This kit did not fit my Ford Explorer XLT. The metal pltaes did not fit and the door is too small!!!!