2004 Ford Explorer repair bend door

Tiny
CJSAAU
  • MEMBER
  • 2004 FORD EXPLORER
Heater problem
2004 Ford Explorer 6 cyl Front Wheel Drive Automatic

Hoe do you replace blend door actuator
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Wednesday, November 11th, 2009 AT 8:56 AM

4 Replies

Tiny
RICKMAR
  • MEMBER
Hi cjsaau;

I was very hesitant to answer your question. Because I know you do not want to hear the answer.
But I noticed it was posted six days ago on Wed Nov 11, 2009 6:56 am and "NO" replies.

HERE IT IS!

The "infamous" Blend Door Actuator ! The original designers engineers at Lincoln/Ford/Mercury should be forced to resign if they are still employed. The Blend Door Actuator has been a big headache for more than a decade.
Because of a little piece of "Plastic" that became brittle from being subjected to heat. You really do not want to read this.

You have to remove your entire dash! The problem goes way back and I am very surprised Lincoln/Ford/Mercury has not changed the design.
There is a shortcut and "BIG" money saver circulating around on the internet about drilling a small 1/8 size hole and using a nail. Whatever it is it "DOES WORK" and will save you $1000.00+
Hang on, I will see if I can find the link so you can read all about it.

Sorry for the bad news;
Rick
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Tuesday, November 17th, 2009 AT 9:22 PM
Tiny
RICKMAR
  • MEMBER
Back again......
Here is the link.
It is a step by step repair with pictures.
A little work but it is better than paying $1000.00+ for the repair.
Or removing your entire dash!!!
http://www.2carpros.com/articles/mitchell1eautorepair-car-repair-manuals
Good Luck;
Rick
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Tuesday, November 17th, 2009 AT 9:42 PM
Tiny
MBELT
  • MEMBER
Thank you for hving an alternative for this. I just bought a 2004 Explorer, runs great, live in Texas. And 3 days ago, when the temps were in the 20's, my heat stopped and I'm sure it is this door. It has a clicking noise, llike something tryingto engage.

Thanks for the question and answer - I'm going to be using it!
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Thursday, December 10th, 2009 AT 2:39 PM
Tiny
RICKMAR
  • MEMBER
Hi mbelt;
I'm glad you will find the quick fix useful.
I can not understand why after 10+ years Lincoln/Ford/Mercury has not changed the design.

$1000+ repair pulling the entire dash out. Unbelievable. But true.

Happy Holidays;
Rick
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Thursday, December 10th, 2009 AT 7:07 PM

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