How to: Replaceing Rear a/c temperature blend door

[theard]

First off, this is how I replaced my rear blend door. This is a guide, and any work you do, you do so at your own risk. I'm not sure which years this design applies to. I have a 2000 E-350 van.
Now that is out of the way, so first:
The problem I developed was that the rear a/c would not work. More specifically, the only thing that would happen would be that heat would blow out from the floor, and no cold air would come out the ceiling vents.
A new blend door will cost anywhere from $90 on up from the dealer. If you can find it for less somewhere else, more power to you! Just make sure that it is the REAR blend door as opposed the the front blend door.

I will show add some more photos once my new blend door arrives.


Also, PLEASE PLEASE PLEASE let me know if I'm unclear or vague on any step or information. I will be glad to clarify on anything I can. Suggestion and comments are also wanted!

Tools:
Philip's head screwdriver
Slot head screwdriver
5/16" and 10mm inch sockets
3" extension
Large torx bit (check to see if it fits the upper seatbelt anchor)
3/8" and 1/4" drive Ratchets

Alright, here we go.

Step1:
The rear of a 15 passenger van will look like this:


You will have to remove the rear seat(s) to get better access to the trim.

Next, you will have to remove the upper seat belt anchor on the rear most seat belt. I used a torx bit to remove it. I'm not sure the proper procedure for reinstalling it correctly. You can gain access to the anchor bolt by prying the plastic cove off the seat belt loop.

Step2:
Remove the rear door rubber gasket trim as such.

Once you have the gasket out of the way, you can pull/pry the black pins out of the trim. These pins hold the trim to the body.

Step3:
Remove the upper trim piece as such. You will have to pull and find all of the connection points. You will also have to remove the pieces that fit around the belts. Those just pry right out. The upper trim piece snaps into the lower trim in many places, and snaps into the body all around the rear pillars.


Step4:
Remove the lower rear trim piece. First, you will have to pry loose the forward trim piece so that you have access to the first screw holding the rear piece to the body. I don't have a good picture of that, but its not hard to do.
this is the picture I do have:

Once all the philip's screws are removed the rear piece will snap off of its body mounts. Once you have the trim off, you will have to carefully set it aside. It will still have the rear most seat belt running through it.(unless you opt to completely remove the rear belt, which I didn't do)
It should look like this:


Step5:
Locate and inspect the vacumn line as it leads up to the actuator.

As you can see the blue vacumn line runs down to the silver actuator.

Step6:
Now we will check the vacumn line. Start and warm up the van and tehn turn the rear a/c on. Disconnect the vacumn line from the actuator and check with your finger to see if it is pulling. Then reconnect the line to thee actuator. If you feel no vacumn, then you have found the issue. Turn the a/c and the vehicle off now.

Step7:
Remove the rear blower motor as such. You will need to disconnect the wiring harness and the rubber motor hose. Then unbolt the 4 5/6" screws holding in the blower motor.


Step8:
Check the linkage between the blend door and the vacumn actuator.

(I have removed the upper duct at this point, but that isn't necessary yet.) You will have to get a flashlight and peer down into where the blower motor was to see the linkage. If the door moves freely, then linkage is probably broken. I checked it be restarting the van and turning the rear a/c on. I then pulled the vacumn line off the actuator again and watched the actuator arm go up and down without moving the blend door.
Now that the linkage issue has been identified, you can turn the a/c and the van off.

Step 9:
This is tricky, but you must remove the 5/16" screw holding in the actuator itself. This screw is on the bottom of the actuator in a very awkward position. I got to it by first removing the 10mm bolts that held the whole rear unit it and then removing the air duct to the ceiling vents. The duct is held in by one philip's screw, so it is no big deal. Now, you must wiggle the whole unit around enough so that you can get access to the screw on the actuator.
WARNING:
There are several heater lines and a/c lines that connect to the whole unit. CARE MUST BE TAKEN not to damage any of these lines. If you damage one, then this repair will become a whole new job. I used a 1/4" drive ratchet and a 3" extension to get my 5/16" socket on the bolt. Once you remove the bolt, the actuator will pop right out. The blend door can be pulled out at this point.


Other photos:
These are a reference for other parts on the rear unit.

Shows the rear heater core and the overall unit.
The rear a/c condensor is under the blower motor.

Shows the relays and the temperature switch.