04 explorer blend door
 

Hi All,
DW has a 04 explorer xlt with no heat .The temp controll blend door tries to move but don't and just clicks.I took apart the front dash to expose the blend door,and helped it close and got great heat .but when u turn off the car it automatically opens again and the clicking starts again.
any ideas on a fix ?.
Can I get to it thru the glove box to disable it closed so she has heat for the winter ?.
any ideas or suggestions would be great .

Thanks in advance ,
Rich.

These blend door motors are known for going bad.

Comon issue unfortunately. Go HERE for instructions on the fix.

Good luck.

CMOS

your 2004 is not like the late 1990s, here is a description i copied last winter off this site.--- you can get to it, then tie-wire the door open at the cam if you want.

2002 explorer blend door--- feb 5, 2007 post

#1 pulled trim piece around radio and heater/Ac control ( unplugged heater/ac control)
#2 pulled center console out ( dont forget to remove to screws from back corner of console, you will have to pop off the corner plastic pieces to see these screws)
#3 removed the bottom part of dash under steering wheel ( 2 screws)
#4 removed metal dash support ( piece that goes from floor to dash behind the consloe, two nuts from floor and two bolts from dash)
#5 pulled the floor vent duck work from driving side ( 2 screws )
#6 removed several screws form dash in middle so it would move a little ( you may not have to do this but I did just trying to make it easier to get to the actuator)
#7 pulled the actuator ( 3 screws) and unplugged)
the top screw on top back corner is rough to get to .

you will need a 1/4 inch ratchet with a 7 and 8 MM socket, I also used a three inch extension on some of the screws.
you will also have to have a 8mm wrench to remove the actuator.


I replaced my actuator, it was not turning at all,appeared that the gear inside was gone.
You do not have to get this from the dealer. Advanced Auto ordered one for me. I had it the next day.I paid 49.88. I also found that a Hanyes manual was helpful also ( 18.00)Make sure you get the manual for the correct year you have. I was told that the 2002 and 2003 where the same. The manual I bought was for both years.The wording was not helpful ( as far as locating the front actuator but looking at the pictures helped alot.

Thank You FTE and to All who contribute their time and knowledge.

After looking at the blend door fix,and reading replys to my post.
I pulled the trim from around the radio, pulled the radio , and front center vent duct
work and panel under steering wheel and borrowed my daughters makeup mirror,
I located blend door motor (with help of mirror) and wiring connector.
What a pita to get to. Turned on the heat and with the help of a short piece of metal snake ,reached in and assisted the blend door up to the closed position and then unplugged the the blend door motor no more clickin ,heat was strong ,blend door can't drop when you turn off the car.(unplugged) DW will have heat /defrost ect. till the full fix is complete .

Thanks Again,
Rich C.

Our '04 Has heat but when the temperature control knob is turned the last little bit a clicking sound starts behind the radio. I'm guessing it is starting to break.

Mine as well Mitch. This will be on my "honey do" list very soon. I'd hate to have the wife driving around with insufficient heat/defrost.
I too appreciate the write up.

Is this stickied anywhere? It's on my honey do list and I hope to be able to find it for our 2003 when I get motivated enough to do it.

I have a 2004 Explorer with a hole in the condensor. Has anyone pulled one of these and how difficult is it

Remove the condenser and radiator as one piece.

Thanks Antony, I guess I know what I will be doing tomorrow, damn

coop

Antony, I just live out in Oakland Ia, slip on out if you want to draw a little blood on your hands, lol,

coop

Blend Door repair
 

I just wanted to add a big thanks. The above list is a great set of instructions. I was done in 1hour and 20 minutes. My ten year old actually did the under dash work. The clicking or tapping noise you here first will not last long. Mine broke within a few days of starting. Easy fix, dont hesitate just get it done. A Ford tech told me I would have to remove the entire dash assembly. This is not true. Thanks Guys!!!!