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Something falling into the ductwork could have jammed the blend door - causing the very very small plastic gears inside the actuator to break off some teeth.

Another reason could be these units are just under-engineered for a long life and break easily with normal usage.

See "Related Questions" for in-depth discussion on replacing actuator motor

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Q: Why do the blend door actuator motors break on Ford Windstars?
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Why no heat in 1999 Jeep Cherokee classic?

it may be a number of things.... the air blend doors get brittle and break then they fall and lay over the heater core blocking the hot air .... or the air blend door actuator may have broken which does not allow the blend doors to switch from hot to cold ..or cold to hot ..... or the heater core itself cold have gone bad


Why did heat stop working on 2000 Ford Windstar?

A common problem is that the blend door actuator or the blend door itself will break. The blend door actuator is just a small motor that opens a vent to allow the warm air to flow, it is cheap and fairly easy to replace with a radio removal tool. A professional could do the repair in less than 15 minutes. See "Related Questions" below for more information on the actuator motor repairs many others have done. However, on my 1999 Ford Windstar, the blend door itself broke. This repair is more costly and more difficult, perhaps $700 to $1000 to replace. I just tied a shoestring to my blend door. When you insert the blend door actuator if there is no slot for it the door is broken and you are up sh... creak. Hope it is the former. Another option is from a company called HeaterTreater - a method to repair a broken blend door without removing the dash. I haven't tried it, but the ideas behind it seem to make sense - and they have lots of videos showing the processes. http://www.heatertreater.net/Windstar%20Listing.html


What is the use of a centrefigual swtich?

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