Well
I just changed my wifes in her Explorer, damn it was not as bad as I thought. But long. You can change it with out removing the evaperator, fan etc. just pul it away some and undo the hiden nuts. The worse ones are the one behind the fan, evap. and the lower one behind Evap. Took me about 10-12 hours. Because Haynes and Clitons does not fully cover it. It spoke to the Service Manager also. He hold me some pointers. If you order one you get evrything but the flap motor, vac valves, heater core. It is a mod item the part number is YL5Z 18471 FA. It is used in both Man and Auto AC/Heaters. In the end with the man you get rid of the adapter plate. I might install the auto after. Just need the auto motor and dash insert. I'll get those at the wreakers. Told cost 205$ Cdn. Not bad for a 25$ part(Flap) the is not avalble due to the mod. I spoke to my Brother in Law, he said due to the mod the flap is stronger. I hope Ford recalls, be nice to get money back. I also change the springs and tie rod ends in my Aero. Not bad for two day jobs

Dave (Cdn Soldier)
94 Aerostar XLT Ext 4LT (Loaded)
98 Explorer XLT AWD 5LT (Loaded)