A/C blowing only through the defrost vents

2003 FORD F-150
270,000 MILES • 5.4L • V8 • 2WD • AUTOMATIC
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SKEPTICHAN
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I have checked the actuator for the blend door and the door itself because I thought that was the problem, but they seem to be working properly. The one thing I have in mind is the vacuum is the problem but maybe someone could point me to a correct solution. While driving downhill sometimes, the max A/C will switch from just the defrost vents back to regular panels. I thought this was a fault in the blend door, so I had to confirm, however the blend door does open/close when the temperature is adjusted. I went to the one-way valve that is under the hood next to the battery and there only seems to be a problem on the intake side where the vacuum is pulling. I do want to point out that panel and floor used to blow cold through the regular vents and floor, but just recently all modes only go through the defrost/top vents. This is why I was leaning towards a vacuum problem. Any help with this problem that I might not be thinking of? I ran through the vacuum line that leads to the intake and it appears to be leaking somewhere. I was thinking about the tiny rubber elbow connector behind the manifold next to the firewall. Maybe someone else could steer me to an appropriate fix. I can also add images of anything if necessary. Thanks
Apr 6, 2022 at 7:38 PM
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STEVE W.
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From your description it sounds like you know the system pretty well, the vacuum leaks are a common thing on those systems due to the temperatures and age of the rubber connections under the hood. The various parts age and come apart. A fast way to test if the issue is a leak inside the truck would be to use a handheld vacuum pump connected to the line that goes to the HVAC system, you can generate a vacuum with that and see if it holds, then move the controls and see if the system operates, test each mode. I think you will find those all work. The leak is likely under the hood, but I have seen the vacuum canisters leak as well. A dirty way to tell if the rubber is an issue is to simply squeeze it and try to rub your fingers together. Most of the time those parts will degrade to the point where the rubber turns to goo or it gets rotted and rubs off like black soot.
Apr 7, 2022 at 12:41 AM
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SKEPTICHAN
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Just tested the line to the firewall and to the engine with a vacuum gauge. When hooked up to the one that leads to the firewall the gauge read about 20 psi and held with engine o. And off with changing the temperature controls. When I did it to the line to the engine the gauge kind of went from about 17 to 25 when I changed the temperature controls and when I shut the engine off, the gauge went to zero. Anything with this?
Apr 7, 2022 at 6:30 AM
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SKEPTICHAN
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Cancel everything I have said up to this point I have figured out the problem! Under the driver's side footwell there is a part that I have found to be the culprit. I guess it would be called the defrost mode actuator. It controls when the defrost/A/C is engaged. With it being up, it’s defrost (it is automatically up). When I pull the metal piece down it switches to the panels and vice versa. I am going to check to see if a fuse is blown to it or even better if it has power at all.
Apr 7, 2022 at 7:25 AM
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STEVE W.
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Think you could take a picture of it and post it, it doesn't sound like something on an F series, unless it is the vacuum motor linkage and unhooked from the actual vacuum motor. Does it resemble any of the images?
Apr 7, 2022 at 8:55 AM
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SKEPTICHAN
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Yes, it’s the middle image.
Apr 7, 2022 at 10:58 AM
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SKEPTICHAN
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I tried to upload a video but I’m not sure that it actually did. Can you see the video?
Apr 7, 2022 at 10:58 AM
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SKEPTICHAN
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Hopefully this will send.
Apr 7, 2022 at 11:03 AM
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STEVE W.
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Okay, the middle one is the panel/defrost motor. It is item 1 in the diagram. Should have a single vacuum line that you found already. Stick a chunk of hose on it and apply a vacuum (even sucking the hose like a straw should work) and see if the vacuum motor works, it should pull the door with it. If it works, then the issue is between it and the control head. If it doesn't move when you apply a vacuum to it the diaphragm inside is bad and you can replace it.

Thanks for the video, I was thinking you meant it was something down at the floor level and was like HMM Ford doesn't have anything there. I miss the days of cable controls....
Apr 7, 2022 at 11:44 AM
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SKEPTICHAN
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Just tried the sucking through the hose and the defrost motor is definitely good.
Apr 7, 2022 at 11:56 AM
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SKEPTICHAN
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This might help too.
Apr 7, 2022 at 12:07 PM
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STEVE W.
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Okay, if it works the issue is that either it's not being controlled through the head or if that lever comes off that easy it shouldn't, should stay on better.
You mentioned that it did seem to work when going downhill? That would also be the time of the highest vacuum levels in the engine so a leak might have been overcome during that time. It could also be the directional check valve has a tear in it and is blocking vacuum one way but not the other as you select the dash vents. Attached are the tests for it.
Apr 7, 2022 at 12:12 PM
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SKEPTICHAN
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Might have found the main problem lmk.
Apr 7, 2022 at 12:15 PM
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STEVE W.
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Looks like the ring you installed might be bad. Wouldn't be the first time a part was bad out of the box these days. I know Brian myself. Great guy and knows the blue oval really well.
A bad seal could act the way it was with the higher vacuum. Check that the slider is actually seating properly under the retainer, It doesn't take much of a gap to cause a leak when you're dealing with vacuum.
Apr 7, 2022 at 1:03 PM
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SKEPTICHAN
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Took it out and sure enough the brand-new o ring did tear some. Could be from rubbing or just cheap. I’m putting it all back together to see if it works right now.
Apr 7, 2022 at 1:19 PM
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STEVE W.
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That can be enough to cause problems when the slide moves. Hope it all works on reassembly.
Apr 7, 2022 at 3:24 PM
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SKEPTICHAN
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Sorry for the extended update but these are all the o rings that I have been going through. Finally got one to work though! Now the door actually vacuums down, and A/C goes through panels. Thanks for the help, I am grateful.
Apr 7, 2022 at 7:26 PM
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STEVE W.
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OOF, looks like they might not be the best. Normally for controls like those I buy a bunch of the correct ones, then apply a thin coat of silicone based grease, just enough to make them hard to hold. That way they can slip easily. But then you run the risk of them twisting if they don't fit the board real tight. But noy that you have it working sounds like you found the problem. Great job. If you ever need other help just come on back.
Apr 7, 2022 at 10:26 PM