2004 Ford Explorer Blend Door Lever Fix

thingiverse

Update The all plastic (PLA) edition of this part that I was using started to break after ~100 cycles. It still continued to function though. Still, I replaced it with the recessed nut version printed with PETG. I recommend not using the all plastic version (at least with PLA). Description This part fixes the broken blend door lever that causes an inability to direct airflow on a 2004 Ford Explorer. Other vehicles may be able to use this fix as well. The part that breaks is 19A574 and I couldn't find it available anywhere. Rather than print out an entire replacement part, I decided to reuse the keyed part and design a shell that slides over it and locks into place. It's not designed to be removable once installed without damaging the 3D printed part. Video of part in action: https://www.youtube.com/watch?v=q9RwTozfP-8 Included Files + 19A574 v10.stl - model I made of the OEM part for reference. + 19A574_cut v3.stl - model showing how the OEM part should look just prior to fitting the fix part + 19A574_fixpart v8.stl - printable part with new plastic pin + 19A574_fixpart_hole v2.stl - printable part with hole instead of pin. Accepts a M4 machine screw (#8 should work as well) + 19A574_fixpart_hole_nut v2.stl - printable part with 4.2 mm hole and recess for a 4 mm hex nut Notes A stronger option (requires an extra part) is to use a metal screw instead of the printed plastic pin. A model is provided with a 3.5 mm hole that accepts a M4 machine screw. A #8 screw should also work. Another option I provide includes a recess for a 4 mm hex nut (7 mm flat to flat) which should result in an even stronger part. This is what I'm currently using. The inner diameter of the hole on the vacuum actuator is ~4.8 mm. Forum threads discussing this issue: https://www.explorerforum.com/forums/index.php?threads/blend-door-or-vacuum-line.323586/ https://www.explorerforum.com/forums/index.php?threads/defrost-door-broken-on-04-xlt-help-needed.255578/ Posters on the forums were mentioning quoted repair costs of up to $800! Just printing this part could justify the cost of a 3D printer. Version History 2019-08-17 add a version with a hex nut to hold the screw in 2019-07-27 increase hole size for part with hole, fix pin size on OEM model, update model orientations 2019-07-16 Initial Release