NHTSA Complaint #10762850 — 2003 FORD EXPLORER

ADJUSTED HVAC TEMPERATURE FROM COLD TO HOT. APPROXIMATELY 5 SECONDS LATER, A LOUD AND REPETITIVE POPPING SOUND CAME FROM THE DEFROSTER VENTS. I WAS STARTLED AND IMMEDIATELY STOPPED THE CAR (ON A 2 LANE HIGHWAY) TO INVESTIGATE. THE BLEND DOOR ACTUATOR IS FAILING. THIS CONDITION WILL CAUSE A LOSS OF CLIMATE CONTROL IN THE CABIN. IT CAN GET STUCK ON HOT OR COLD OR ANYWHERE IN BETWEEN. IF IT GETS STUCK IN THE COLD SETTING, THE WINDSHIELD DEFROSTER WILL NOT WORK WHICH COULD CAUSE AN ACCIDENT DUE TO LOSS OF VISIBILITY. IF IT GETS STUCK ON THE HOT SETTING, HEAT-SENSITIVE PASSENGERS MAY BE INJURED BY HEATSTROKE IN THE SUMMER MONTHS SINCE AIR WILL ALWAYS FLOW THROUGH THE VENTS WHEN THE VEHICLE IS MOVING.