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How to i replace the Heater blower cable on a ford mondeo 1996 TD?

My heater is stuck on cold, the switch turns freely but there is no resistance like before, so the flap isnt opening at all and i only have cold air blowing out. It was stuck one day and i forced it to open so i can only assume that the cable has snapped or has come off at one end ??? Is it possible that i can manually open the flap and have it on hot all the time for now ? Where is it located and how to i check
PLEASE HELP !
shankly9, October 2008
Hopefully you'll find that the cable is kinked behind the control knob, not broken.

Bad news is you need to first remove the console around gearstick to get centre console out to carefully straighten the cable.

You can check both ends of the cable by first removing your radio and looking up behind control knob with a torch for one end. Other end is connected to a lever affixed to centre housing to the left(and above) of the clutch pedal. You'll need to have your head in the floor well to see it!

Make sure you can move this lever or any fix will be very temporary(try and use your other hand to move control knob at the same time to avoid possibility of further damage or kinking)! Alternatively, if you wish to bodge the heating full on, the cable at the lever end can be removed easily. Pull it way from the lever towards the clutch pedal and then come up with a way of sticking the lever in the warm position(it naturally springs back to cold).

I'm reasonably certain that you'll find your cable has developed a nasty kink behind the control knob, like mine did, which means it isn't opening the flap enough to let hot air through the system.

The cable attachment to the control knob looks very flimsy, so it will need to be straightened with great care but I managed it yesterday and the fix worked fine.

Bearcub, November 2008
link Click here to see other fixes for Ford Mondeo.