What does a blend door motor look like - and how to replace it on a 2004 Ford Taurus - Mercury Sable?

Answer 1

Judging by the picture of it, and what I've seen of other actuators, it looks to be a 4x4x1" black device, 4 mounting screws and 1 wire connection port up behind the radio area.

Just for the fun of it, here's the replacement procedure, para-phrased:

1. Remove the lower trim panel from both sides of the center dash/console.
2. The actuator motor should be visible/accessible
   
   
3. Unplug the wire harness connector
   
   
4. Take out the four retaining screws - likely to be 5/16ths
   
   
5. Remove the blend door actuator
   

Since I haven't done of these personally, I'll suggest that you might find it even easier to pop-out the radio/heater control panel. If you already have the $4 radio tools, it'll only take 2 minutes and *might* make access even easier. See "Related Questions" below for taking the "radio" out.

Essentials: Flashlight (or young eyes), some aspirin for the bending over & twisting, band-aids for any possible scratches, and small socket set or nut driver.