This procedure covers the removal and replacement of the recirculation door actuator in the HVAC system, which controls the fresh air vs recirculated air blend for cabin climate control.

Warnings

Tools required

Parts

• Recirculation door actuator × 1 — Use OEM Ford motorcraft part
• Panel retaining clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key/fob from vehicle
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery terminal and wait 2 minutes for airbag system capacitors to discharge
5. Position driver seat fully rearward for access
6. Set work light for visibility under lower dashboard area

Procedure

1. 1

   Remove lower driver side dashboard panel
   Locate and remove the lower dashboard knee bolster panel below the steering column. Remove the two 7mm screws at the bottom edge and carefully pull the panel downward and away to release the upper retaining clips. Disconnect any electrical connectors for courtesy lights if equipped. Set panel aside in safe location.
2. 2

   Remove lower instrument panel insulator
   Remove the felt or foam insulation panel behind the knee bolster. This is typically held by push-pin clips. Carefully release clips using trim tool and remove insulator to expose HVAC ductwork and components.
3. 3

   Locate recirculation door actuator
   Using your flashlight, locate the recirculation door actuator on the driver side of the HVAC housing, near the blower motor assembly. The actuator is a small motor with a rotating arm and electrical connector. It is positioned on the left side of the main HVAC case, typically visible once lower panels are removed.
4. 4

   Disconnect actuator electrical connector
   Press the locking tab on the actuator electrical connector and carefully pull straight out to disconnect. Do not pull on wires. If connector is difficult to access, you may need to reach around or use needle-nose pliers to depress the locking tab.
5. 5

   Remove actuator mounting screws
   Remove the three mounting screws securing the recirculation door actuator to the HVAC housing using an 8mm socket or appropriate driver. These screws may be accessed from different angles, so use extensions as needed. Place screws in magnetic tray to prevent loss.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
6. 6

   Remove actuator from HVAC housing
   Carefully rotate the actuator counterclockwise approximately 30 degrees while gently pulling outward to disengage the actuator arm from the door linkage. The actuator should slide out of its mounting position. Avoid forcing; if resistance is felt, verify the arm is properly disengaged from the door mechanism.
7. 7

   Inspect door mechanism
   With actuator removed, use flashlight to inspect the recirculation door linkage and door itself for damage, binding, or debris. Manually move the door arm through its full range of motion to verify it moves freely. Clean any debris from the door mechanism or housing.
8. 8

   Install new actuator
   Position the new recirculation door actuator near the mounting location. Align the actuator drive arm with the door linkage slot, ensuring proper engagement. The actuator may need to be rotated to align the arm properly. Gently push actuator into position on the HVAC housing.
9. 9

   Install actuator mounting screws
   Install the three mounting screws finger-tight first to ensure proper alignment. Once all three screws are started, tighten them in a cross pattern to specified torque using 8mm socket. Do not overtighten as housing is plastic.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
10. 10

    Reconnect electrical connector
    Reconnect the electrical connector to the actuator, ensuring it clicks fully into place and the locking tab engages. Gently tug on connector to verify secure connection.
11. 11

    Test actuator operation
    Reconnect the negative battery terminal. Turn ignition to ON position without starting engine. Set climate control to recirculation mode and then fresh air mode several times while listening for actuator operation. You should hear the actuator motor run and feel air source change. If using scan tool, perform HVAC actuator self-test.
12. 12

    Reinstall lower panels
    Once actuator operation is verified, reinstall the lower insulator panel by pressing clips into their mounting holes. Reconnect any courtesy light connectors if applicable, then align the knee bolster panel and press upper clips into position. Install the two 7mm lower screws and tighten securely but do not overtighten plastic threads.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all trim panels are properly secured and aligned before final fastener installation
3. Replace any broken retaining clips with new OEM clips
4. Double-check that no tools or parts were left in dashboard cavity before closing panels

Verification

• Start engine and bring to normal operating temperature
• Cycle climate control between fresh air and recirculation modes multiple times, listening for smooth actuator operation without grinding or binding
• Verify proper airflow changes when switching between modes - recirculation should reduce outside air intake
• Check that no rattles or loose panels are present in dashboard area
• Use scan tool to verify no HVAC-related DTCs are present
• Confirm climate control system responds normally to all temperature and airflow commands

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