Trouble in the air

WE REFERRED your problem to Mark Lynch at Carcool Airconditioning and his advice was: The fresh air/recirc duct has been a problem since the 1984 XF Falcon. The duct was revised by Ford about the 1993 ED by increasing the thickness of the actuating arm, but then the duct broke at the pivot shaft instead of the arm. The easiest way to solve the problem is with a 5cent self-tapping screw to lock the flap in permanent recirc because this stops the constant flow of cold air. If you want to persist with a fix use a modified early duct with a strengthened actuator arm in lieu of a new part.