Ford Mondeo Mk2, Faulty Air Distribution Control, Air Flow defaults to Windscreen.

Ghia X 2.5 V6.

19.8.15

The system operates by taking a vacuum air pressure from the servo assist in the engine compartment through a Vacuum Tube to the Air Distribution Control switch and Air Conditioning Blower switch, on to a series of Vacuum Tubes to Air Valves or gates which are opened or closed to direct Air Flow around the Dash Board and Floor vents.

The problem arises in that there is a gungy sealant in the Air Conditioning Blower switch which over time deteriorates and is sucked into the Vacuum Tubes from where it is then sucked into the Air Distribution Control switch, reducing the opening of the Air Valves, and eventually blocking the tubes causing air flow to default to the windscreen. The solution is to locate the blockage and clear it.

The other potential problem is that at the end of the Vacuum Tubes there are small plastic elbows which connect to nipples on the Air Valves and over time these can loosen, allowing air to leak in to the system, these need locating and reinserting.

Remove the Radio CD player, look into the cavity and locate the 2 small Phillips screws at left and right side, remove the screws, and carefully lever forward the fascia board, there are 2 clips at the top, giving sight of the Air Distribution Control switch and Air Conditioning Blower switch connections.

Using nimble fingers and a torch if necessary locate the 1 clip at the top of the Red Electrical connector at the top of the Air Distribution control switch, lever it up and push off the connector. Then look for the 2 clips either side of the Air Distribution control switch securing the Vacuum Air tube connector and lever these a fraction of a time while gently pulling the connector, the connector will eventually free itself.

Then look for the similar 2 clips either side of the Vacuum Tube connector on the Air Blower switch, and lever these a fraction at a time while gently pulling the connector, the connector will eventually free itself.

Start the engine and feel with the end of your finger pressed against the Connector end for suction from the Black Vacuum tube. If you have suction then the problem is elsewhere.

Go to the Drivers side foot-well and look up to where the side of the Clutch Pedal would be and see the small single Star Screw in the support arm from the plastic Vacuum Box , remove the screw and the box will free. Pull off the large Straight Connector from the box, use a small light brush, and smear light oil around inside the Connector and reinsert it to the nipple. Do the same for the small Elbow Connector, and reattach the Vacuum Box after noting the White Vacuum Tube which leads from the Air Distribution control and here disappears up into the bulkhead above the Vacuum Box where it attaches to a Vacuum Air valve opening and closing air flow either to outside or recirculating within the cabin. On the end of this White Vacuum Tube there will be another Elbow Connector but it is difficult to locate so leave it.

Go to the opening where the CD Player sat and look to the lower left side where you will see a round Silver Cylinder with 2 Vacuum Tubes, this is one of the Air Valves or gates, the Grey and the Blue Vacuum Tubes connect here, pull off the Elbow Connectors one at a time, lightly oil the inside of the Elbow Connectors, and reconnect.

Go to the drivers side foot-well and remove the Glove Box, open it, and pull straight back, then look for another round Silver Cylinder with 2 Vacuum tubes, Red, and Yellow, remove the Elbow Connectors and one at a time, lightly oil the inside of the Elbow Connectors, and reconnect.

Now take a length of 15 Amp Fuse Wire and push this gently but firmly through the Vacuum Tube Connectors which were located at the back of the Air Distribution control switch and the Air Blower switch and withdraw looking for any sign of green or grey gunge, if you see some, then reinsert the 15 Amp and keep doing this removing the smear of green grey gunge till the Vacuum Tube seems clear.

Now test, reconnect the Connectors to the back of the Air Distribution control switch and Air Blower switch and start the engine, test the air flow to the air vents, if this has not fixed the problem remove the Vacuum Tube connector from the back of the Air Blower switch and blank it off with a short length of Electrical tape, then restart the engine and check again, if this fixes then the Air Blower Switch is gummed inside with the green gunge and probably needs replacing, though you could leave it at that point, the only loss is that the Air in cabin recirculation is no longer functioning.

If that does not fix the problem then replace the Air Distribution control switch, these are available new GBP22, or from Ebay, the Air Blower switch which could be where the original problem arose in the green grey gunge is no longer available new.

If you need to remove the switches using a small electrical screw driver see the small indent mid way at each side of the Air Distribution control switch, these are the clips securing the switch to the facia board, press in one side clip till the switch moves away on the one side, place a second screw driver into the gap created, then repeat the procedure on the other side of the switch, which will then fall away. Look for the small clips securing the upper Electrical connector and the lower Vacuum Tubes connector and with care and patience, remove these from the back of the switch.The Air Blower switch is secured with a screw, use a mirror to locate.

Best of luck.

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Morning Vegaone

I still run a MK 2 and this fault occurs quite often, I found that by spraying WD 40 ( not too much )into the intake with the fans on 3 setting and then adjusting the air flow switch it resolved itself, they are prone to sticking, good luck

Rammer

Tried this but no luck.

To follow this lead Spraying WD40, first remove the Pollen Filter to the instruction Manual, remove the Right Side Vent near the Windscreen, however, looking at the rear of the Multi Way Switch the connections are Electrical and not Cable mechanical.

So, as all 3 positions are not working and the Air Distribution Control has defaulted to Wind Screen only, then the fault must lie elsewhere and must be electrical rather than a jamming flap door.

I checked all Fuses, all OK, will post solution when I find it unless someone has another idea.

Andy

I also when thinking back removed the carpet to access the blower I think it will be on the drivers side in UK I think I also tried spraying from that point as well, try spraying the contacts on the control with electrical spray, failing that I have a spare control panel here but I live in France good luck

George