No problem with cooling or heating, but the air didn't go where it was
supposed to go since we bought it Aug 08. Took awhile to figure out how to
get to the dash air. The lid with the 2 cup holders has to be lifted up and
removed at the hinges, then some ducts on the right side. Next lift out the
board with the electronic box (part of the backup camera display). Had to
disconnect some of its cables to get it out. Now you can get to the screws
that hold the part with the snack table. Once that is removed you have
partial access to the dash air. It's just a sheet metal box that contains
the ac evaporator and the heater core. Around the outside are several
outlets for the air ducts. Also inside the box are 3 flat sheet metal doors
that divert the air to where it is supposed to go.
I'm not sure where the
blower is located as I could not see it, it's either up front or in the box.
The diverter doors are operated by small 12v geared electric motors.
Reversing the 3 motors to move a door in the other direction is done by
changing the polarity. This is handled by a simple printed circuit relay
board with 3 small relays that switch the polarity. Each motor is attached
to a door by an arm of some sort clamped to a shaft with a bolt. Not sure
if there is a stop in the gear mechanism, but the motor stops when the door
can't move anymore. Current continues to flow to the motor, but evidently
the motor can take it without burning out. I had to remove several small
sheet metal screws and a panel to be able to see what was in the box and
what was happening. Found that one of the doors never moved.
Testing with a
voltmeter and some wire attached to a 12v power source revealed that the
motor was ok and that a relay on the relay board was the problem. I had to
unsolder 2 wires at the motor to test it. I couldn't find a relay that
matched, or I would have replaced it, but Foretravel had a relay board for
about $70 with shipping. Installing the new board fixed it and now air goes
where it is supposed to.
The problem could just as easily have been a bad
motor, loose crank arm, etc. Some other things I found out, even with the
Dash air switch in the off position, current is still going to the small
motors until the ignition switch is off. It takes the motors about 5-10
seconds to move the doors to the selected position. The Fresh, blend,
recirc switch is only 2 positions not 3, and I couldn't figure out which was
which, but recirc seems to cut off most of the outside air. Leaving the
switch in recirc before turning off the ignition in cold weather might help
keep out cold air when parked (unsure of this).
Both full sides of each door
is covered with a thin piece of foam that compresses to form a seal at the
edges. At 13 yrs of age the foam needs replacing, but I didn't do it, just
vacuumed off the loose stuff. Passing this along in case you have the same
problem. Your Foretravel could be built differently even the same model.