Model originally uploaded to Thingiverse at https://www.thingiverse.com/thing:3751515.
UpdateThe all plastic (PLA) version of this part that I was using (19A574_fixpart v8.stl) started to break after ~100 cycles. It still continued to function, though (see pictures). 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 (to defrost, or upper or lower vents) on a 2004 Ford Explorer. Other vehicles may be able to use this fix as well. The part that breaks is 19A574 and I could not find it available anywhere. Rather than print out an entire replacement part (it is fairly complicated, and would most likely break soon as the OEM part tends to do), I decided to reuse the keyed part and design a shell that slides over it and locks into place. It is 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. Guessed what the broken off end looked like because I couldn't find the piece.
- 19A574_cut v3.stl - model showing the 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 - untested)
- 19A574_fixpart_hole_nut v2.stl - printable part with 4.2 mm hole and recess for a 4 mm (7 mm flat to flat) 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. I used a M4x12mm screw.
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 am 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.
I have limited production capacity, but I do offer the part for sale, complete with nut and screw here: https://www.etsy.com/listing/767020476/ford-blend-door-lever-fix
Version History2019-08-17 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