grease everywhere from what?

[mmh64]

It's nice weather today and LH temperature blend door actuator was on shelf. Decided to install it. After removal noticed what looked to be white lithium grease everywhere above the actuator and some melted and starting to drip below. What is all this from? Sloppy assembly workers ? Should I just wipe it off , install actuator and don't look back? Or should I be concerned?

 

[mmh64]

Update on this. Cleaned area best I could. The image does not fully depict what a mess it really was up there. Upon futher investigation it appears the oil has started to separate from the grease globs. It had tracked to the pivot point of brake pedal then dripping on floor mat. I have noticed a few spots on mat before but didn't think to look if it originated from the car. I still don't know what caused it. It's hard to tell where it's coming from. It's oozing from the hvac duct work somewhere above that blend door actuator. Any way I installed the actuator. Heat works good and no more clickity-click noised. Hope it is just from sloppy assembly worker. Or just maybe over greased a component.

 

[SHOdded]

Does seem to be the result of an oversight than a design flaw. Very weird!

 

[rcryniak]

FoMoCo got gooey. lol

 

[Pintony]

Update on this. Cleaned area best I could. The image does not fully depict what a mess it really was up there. Upon futher investigation it appears the oil has started to separate from the grease globs. It had tracked to the pivot point of brake pedal then dripping on floor mat. I have noticed a few spots on mat before but didn't think to look if it originated from the car. I still don't know what caused it. It's hard to tell where it's coming from. It's oozing from the hvac duct work somewhere above that blend door actuator. Any way I installed the actuator. Heat works good and no more clickity-click noised. Hope it is just from sloppy assembly worker. Or just maybe over greased a component.

Hello mmh64,
Is your SHO a 2010?

 

[mmh64]

Hello mmh64,
Is your SHO a 2010?

Yes 2010 non pp

 

[Pintony]

Yes 2010 non pp

Hello mmh64,
Did you get any photos of the part you replaced?
This is good info as these cars get older and require parts replacements.
How long did it take to make this repair and is it something that some members should leave to Ford?

 

[mmh64]

Hello mmh64,
Did you get any photos of the part you replaced?
This is good info as these cars get older and require parts replacements.
How long did it take to make this repair and is it something that some members should leave to Ford?

This is the old part,new bag with part number. Blend door actuator is common failure with fords. Nylon gears strip, starts jumping teeth making click click noise. Lots of info with search function on replacing this part. OEM part is readily available from many online resources as low as $19-20. Most dealers stock this item for less than $40. Easy job for diy. 15 minute job for me after I cleaned up the area. Two 8mm bolts and electrical conector. Symptoms for mine were improper heat distribution and clicking noise.

 

[SHOrod]

So common of an issue that I even modeled the gear for 3D printing. The same part failed in my wife's MKT within a month of failing in my SHO. The blend door motors on the driver's side are not bad to replace, but the ones on the passenger side can be quite a bit more challenging. To replace the passenger motor on the MKT, the service manual says to take out the dash. I managed to replace it without pulling the dash but it required a couple of non-standard tools (low profile right angle driver and thumb ratchet driver).

If anyone is interested in printing the blend door gear, I think you should be able to view it at this link.

-Rod