Join Date: Dec 2011
Location: Conroe, North of Houston
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I just finished replacing my blend door actuator tonight. It was the one on the passenger side. There are a few things that are important to know when you are removing the dash. The instructions above are pretty complete so I will just add a few points to it.
1. The bolts under the 4x4 panels up by the windshield like to drop behind the dash once you get them out. So grab them with a magnet and take them out before you lose them. Just a point about those bolts, there are two on the driver side and one on the passenger side.
2. There are three (if I remember right) wiring harnesses on the passenger side that also need to be disconnected to move the dash out far enough to get to the blend actuator.
3. The plug mentioned in the door jam is only on the driver's side. That bolt is hard to get to and is easiest accessed from outside the truck. Stand in front of the driver side door, open the door all the way and you can see the bolt head. Use a magnet to keep it from dropping into the frame.
4. The dash is very heavy. Be sure to have someone to help you put it back on. Lift it up slightly higher than you think and it will fit right back on.
5. It is best to remove the grab handles from the A pillar or the dash won't want to come out. Just remove the two caps and take the 4 bolts (8mm socket) on each side out then remove the entire plastic panel.
This wasn't too bad of a job. I have never done it before and found all of the bolts just fine. My truck only had two inside the door frame on the passenger side and three on the driver side. The part was $32.36 from ford and the dealer wanted $200 in labor to replace it (Gullo Ford in Conroe, Texas). The entire job took me less than 2 hours.
Other than the few points I made here, the instructions above are great. Best of luck doing this repair and don't forget to re-attach your steering column to the steering shaft that goes back through the firewall.
For the record, my truck is a 2008 F-250 CC SWB King Ranch with dual auto air. The ford part number ends in 616.
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2008 F-250 CC SWB King Ranch 4x4, 3.73, Job 3, stock looking so far...
B&W Gooseneck, Firestone Air Bags
Tows 2013 Voltage 3200 Toy Hauler
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Last edited by HHR124; 02-24-2012 at 05:57 PM.