Vehicle: 2002 ML 500, 1994 Ford Explorer donated to Doctors without Borders
Location: Boston, MA
Posts: 2,051
I had this problem. My A/C would randomly blow extremely hot air when I had it set to cold and cold air when I had it set to hot. The dealer replaced the flap assembly under aftermarket warranty. ~$2000.
The cost was not in the part, but in the hours of labor to remove the whole dash assembly and remove everything but the steering wheel.
43sqd: Thanks for point out the TSB. I have a 02 ml320 with 50K miles. I have the A/C-ticking Noises/Center Vent. Please tell me how to get the content of the TSB that you have posted. I followed the link that you provided but could not get the contet at Wolfgang's ML Page. Thanks.
I had this problem. My A/C would randomly blow extremely hot air when I had it set to cold and cold air when I had it set to hot. The dealer replaced the flap assembly under aftermarket warranty. ~$2000.
The cost was not in the part, but in the hours of labor to remove the whole dash assembly and remove everything but the steering wheel.
Bogie, this is what I am trying to explain. Everybody is charged for removal of the entire dash board , but in reality the entire time it takes to fix this particular problem is approx 45 mins. Again, there is no necessity for the removal of the dash. It's one of M/B cash cows.
The repair procedure for this problem is to removed the instrument cluster, NOT THE INSTRUMENT PANEL, AND THE CENTER VENT ACTUATOR MOTOR IS RIGHT IN FRONT OF YOU. Then remove the two screws holding the small motor, pull out the broken plastic drive sleeve, insert a new one, replace the motor and the cluster. All is required is about 45 mins. tops, if that.
I hate to be the bearer of bad news, but if anyone paid more that $200 for this, you had better call the police because you were robbed.
43sqd: Thanks for point out the TSB. I have a 02 ml320 with 50K miles. I have the A/C-ticking Noises/Center Vent. Please tell me how to get the content of the TSB that you have posted. I followed the link that you provided but could not get the contet at Wolfgang's ML Page. Thanks.
I only posted the link this morning to show you that there was a TSB on your problem. I have the actual printed TSB and a separate repair instruction and it was obtained from Alldata, which is paid for on a monthly basis. The problem with Alldata material is that it can be copied off the screen but you cannot email it or copy and paste it. Alldata prevents you from doing this. I do not have a scanner along with my copier, so the only thing I can do is mail you a copy of both the TSB and repair procedure. PM me with your name and address and I will send it to you.
I fixed this annoying problem today. Thanks to 43sqd for giving me the clue that we can do this without going to dealership or removing the dashboard.
Problem: occasional clicking noise from the center of the dashboard and/or central vent malfunction.
Solution: Replace the broken holding fixture (Part number: 163 683 0954) between the actuator motor and center air duct flap. Cost: $24
See picture of the broken fixture together with the new one on the left. The notch is broken. Therefore motor doesn't stop and makes clicking noise.
These are my instructions. I tried to get the TSP but stealership wouldn't give it to me.
1) First you need to remove the instrument cluster. See instructions. I did not disconnect the battery. 2) Easily take the insulation blanket out in order to have access under the dash. 3) You will see the center duct actuator motor on your right hand side. It is mounted to the left side of the center duct. See the picture of the motor removed. 4) Unplug the power connector and remove the motor. Tip: There are three screws and two of them are difficult to reach and see. I used a flexible extension attached to a 7/32" socket head. This is the difficult step since your arms will be deep inside the dash. 5) You will see the holding fixture that is maneuvered by the motor's shaft. See picture of the duct. Remove the fixture and check if it's broken. Make sure you have the new part and replace it quickly. I drove the car without this in place for two days and the flap inside the duct shifted. I had to remove the nozzle to position the flap inside with the holding fixture again. Also do not loose the tiny white sleeve inside the fixture. 6) Install everything in reverse order.
Linear Mode
