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This sounds like the common blend door problem on this model. The plastic door is driven by a DC motor that is geared too strong for the application. Over time the motor will overstress the door and break the connector. The same plenum box is used on the F150 and you can find information on the problem by searching for that model also. There is a video available on YouTube showing how to diagnose and repair the system. It is an expensive repair at the dealer, but you can repair it yourself with minimal skills. You can follow links on my bio page for pictures and additional information on how to diagnose and repair the problem.

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Q: Heater blows cool air in 2000 Lincoln navigator?
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