TECHNICAL SERVICE BULLETIN Bulletin Number 42/05

Passenger and Light/Medium Commercial Issue Date: 20 December, 2005

Circulate to Service Manager Parts Manager Foreman Receptionist Technicians

X X X

Subject/Concern: HVAC Loss Of Temperature Control

Models: BA Falcon & SX Territory Built from Job#1 to 06/09/04

Summary
Cause: System operation may cause the HIM coupler to disengage.
Action: As detailed in Service Procedure.
Warranty Status: Reimbursable within the provisions of the Warranty and Policy Manual.

Parts Required
Description Part Number Quantity
Single Zone Air Mix Door Shaft Kit , or BA 19K752 AKT 1
Dual Zone Air Mix Door Shaft Kit BA 19K752 BKT As Required
Molycote PG54 Silicone Grease (or equivalent) Dealer Supply -

Service Procedure
THIS TSB SUPERCEDES 16R/05 PLEASE DESTROY ALL PREVIOUS COPIES
This TSB has been re-released due to changes in the standard repair times.

THIS TSB MUST BE APPLIED ON A CUSTOMER COMPLAINT BASIS ONLY

Concern Description:
Some vehicles may experience loss of temperature control on Single Zone air conditioning, or a loss of temperature
control on LHS on Dual Zone climate control systems. This may be due to a number of causes including:
• low refrigerant charge,
• inoperative HIM,
• HIM coupler disengagement
• air mix shaft inoperative

The following procedure should be used when diagnosing and replacing an inoperative air mix shaft. The procedure
specifies how to replace air mix shaft(s) without having to remove the HVAC assembly.
Service Action:
1. IDENTIFICATION OF INOPERATIVE AIR MIX SHAFT:
Air mix shaft replacement must only be conducted once the air mix shaft has been diagnosed as inoperative.

1.1 HIM Operation – An inoperative HIM may produce similar symptoms to an inoperative air mix shaft including lack
of temperature control. Check HIM is operational by (with engine at operating temperature and the ignition in ACC)
varying the temperature control between HOT and COLD while monitoring temperature and listening for the HIM
operating. A lack of temperature control or HIM motor noise may be due to an inoperative HIM. Continue HIM
diagnosis as per workshop manual.

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1.2 Air Mix Shaft Coupler Disengagement – An air
mix shaft coupler disengagement can cause a loss of
temperature control function. The air mix shaft coupler
can be inspected using a mirror from the passenger
footwell as shown.

A coupler may be disengaged if end protrudes past the

HIM by 9-11 mm. If the air mix shaft coupler is found to
be disengaged, continue diagnosis as per workshop
manual.

Air Mix Shaft

Coupler

HIM shown with IP removed for clarity

1.3 Air Mix Shaft Operation – An inoperative air mix

shaft will not rotate when the temperature control
setting is cycled between hot and cold. Air mix shaft
operation can be observed from drivers side footwell,
as shown.

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For single zone A/C, the air mix shaft is seen through
the HVAC case.

Air Mix Shaft

For dual zone A/C, the air mix shaft is seen at the edge
of the electric motor.

Air Mix Shaft

2.0 AIR MIX SHAFT REPLACEMENT

NOTE: THIS PROCEDURE DOES NOT REQUIRE REMOVAL OF THE HVAC ASSEMBLY, DEGASSING OF THE
A/C SYSTEM OR DRAINING OF COOLANT.

Step1 Set the ICC to 'Recirculation' and 'Floor' modes. Remove instrument panel as specified in Chapter 501-12 of
the workshop manual.

Step 2 – Detach the HVAC upper mode outlet panel (6

x self tapping screws, 2 x clips)

Upper Mode
Outlet Panel

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Step 3 – Disconnect the foot / rear console duct rod
from the lever at the vee duct.
Vee
Step 4 – Remove the HIM assembly (3 x self tapping Duct
screws)

Step 5 - Remove the vee duct from the front section of

the HVAC (6 x self tapping screws)

For Single Zone A/C, follow Step 6. For Dual Zone A/C, follow Step 7.

Step 6 – For Single Zone ONLY

Step 6A – Move the temperature control dial on the

interior command centre to the full hot position. At the Door stop
full hot position the door seal edge must be engaged in locators
the door stop locaters moulded into the case. (4 in total)

Step 6B – From the RH side of the HVAC locate the

end of the air mix shaft. By using a suitable 6mm pin
punch and by holding your thumb against the RH outer
door pivot, push the air mix shaft through to the LH
side until approx half of the shaft is removed.

Note: Applying an opposing force against the door

pivots will reduce the likelihood of breakage

RH Outer Pin Punch

Door Pivot with 6mm
Shaft

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Step 6C – Using your thumb, apply pressure against
the LH side door inner pivot then continue to remove LH Door
the air mix shaft by pulling it through the LH side. Outer Pivot

LH Door
Inner Pivot

Step 6D – Inspect new air mix shaft for plastic "flashing" which may have been left over from the manufacturing
process. Carefully remove any excess plastic with a sharp blade. Apply silicon grease to the 4 door pivot
openings with a small brush to aid mix shaft installation.

Step 6E – Install the air mix shaft through the opening into the LH door outer pivot ensuring that the locaters on shaft
and pivot line-up. The shafts will only locate in one position.

Step 6F – Continue pushing the air mix shaft through

the LH door outer pivot while applying pressure to the LH Door
RH door inner pivot. Inner Pivot
Note: You may need to apply a light load to the
passenger side door outer pivot if the shaft is hard to
insert.

RH Door
Inner Pivot

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Step 6G – Push the air mix shaft into the RH outer
door pivot.

Note: If the shaft is hard to insert into the RH outer

door pivot, use an 11 mm extra deep socket with an
extension bar and apply a light force to the end of the
extension bar by hand to drive the shaft inwards.

11mm extra
deep socket

Note: The correct shaft insertion depth of the shaft is Case

achieved when the plastic pointer attached to the shaft Recess 3.0mm measured
drive spline is 3mm from the case recess face to the between underside of
shaft flange underside. shaft flange to the case
recess

Shaft
Flange

Continue to Step 8.

Step 7 – For Dual Zone ONLY

The Dual Zone A/C system has two individual temperature doors for both passenger and driver side while the Single
Zone A/C has a single temperature door. The following procedure explains how to replace both Dual Zone LH & RH
mix shafts.
NOTE: The BA 19K752 BKT Dual Zone Mix Shaft Service Kit contains only one mix shaft per kit, which is
interchangeable between passenger and driver's side. Only replace the inoperative mix shaft. If both mix
shafts are inoperable, order 2 x BA 19K752 BKT kits to complete the repair.

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Step 7A – Passenger side air mix shaft. Apply
pressure with your thumb behind the RH inner door RH Door
pivot, then using a medium flat blade screwdriver push Inner Pivot
the shaft through the door pivot.

Note: Applying an opposing force against the door

pivots will reduce the likelihood of breakage.

Step 7B – Push shaft to the left to remove.

Step 7C – Inspect new air mix shaft for plastic

"flashing" which may have been left over from the
manufacturing process. Carefully remove any excess
plastic with a sharp blade.

Apply silicon grease to the 4 door pivot openings

with a small brush to aid mix shaft installation.
Install the new air mix shaft into the HVAC case in the
reverse order of removal.

Note: If a resistance is felt during installation of the air

mix shaft, apply pressure to the RH door inner pivot.

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Step 7D – Drivers side air mix shaft. To replace this
shaft the electric driving motor will have to be removed
(3 x self tapping screws). Using the flat blade
screwdriver, push the shaft through the door pivot.
Ensure the locators on the shaft and pivot line up.

Note: Applying an opposing force against the door

pivots will reduce the likelihood of breakage.

Continue to Step 8.

Step 8 - During the dismantling of the vee cover from

the HVAC at Step 5, and the subsequent removal of Spring Mechanism
the floor / console mode door assembly, the outer INCORRECTLY fitted,
doors may become disconnected from the return shaft connection exposed
spring mechanism. This will cause faulty operation of
the 'foot mode'. Inspect return spring mechanism
before refitting the vee cover.

Using a flat blade screwdriver relocate the coil section Spring Mechanism
of the spring back onto the door pivot boss. CORRECTLY fitted, shafts
connected completely

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 When refitting the vee panel back onto the HVAC,
ensure the LH foot / console mode door locater is Panel Recess
correctly fitted into the panel recess.

Step 9 – Check that all the door pivot points are straight
and in their correct positions. Grasp the air mix shaft and
move the doors from Hot to Cold, ensure the doors move
freely in each direction, door end stops are reached and
the doors seal against the case.

Step 10. - Before installing the HIM, remove the

existing air mix shaft coupler and fit the new
coupler provided in the service pack. Push the
coupler all the way in until the shaft end is protruding
past the face of the HIM. This will aid in air mix shaft
to coupler fitment when fitting the HIM to the HVAC.
Air Mix Shaft
Coupler

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 Step 11. - Refit the HIM to the HVAC. Maneuver the
HIM into position and insert the HIM mode levers into
the HVAC door levers and the blower speed heat
sink into the case.

Secure the HIM to the HVAC (3 x self tapping

screws). Reconnect the floor / console rod. Push the
coupler end through the HIM and onto the air mix
shaft spline. Operate the air mix door by hand to
engage the shaft splines.

Step 12. – Refit Vee Duct and HVAC upper mode outlet panel.

Step 13. – Refit the instrument panel and check the operation of all climate control and air distribution functions.

Operation Number/Standard Repair Time

Time
Operation Description Operation Number BA Falcon SX Territory
Instrument panel remove & install
TSB04205 3.4 hrs 3.5 hrs
Diagnosis & air mix shaft replacement

Repair/Claim Coding
Warranty Claim
Enter 05016 in box "X" of warranty claim to reference this TSB. Causal Part Condition
For Single Zone BA19K752 AKT 01
For Dual Zone BA19K752 BKT 01

Please direct any questions regarding to this Technical Service Bulletin to the Dealer Technical Service Hotline on
1300 733 600.

Service Engineering,
Ford Customer Service Division.

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