04 Explorer Actuator Door?
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New User
Joined: Jan 2007
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04 Explorer Actuator Door?
Just took my truck to the dealer because I have no heat...and was unable to find anything remotely close to the diagrams and what not from other post regarding the blend door. Well the dealer said it's my actuator (sp?) door that's probably stuck so only cold air is coming through and the estimated cost is $800 dollars. Please tell me this is a part I can get myself and try to fix. Or that there is a Chilton's Book that can direct me on how t fix it. I've searched for an 04 Explorer book from Chilton and have yet to find one. Any help will be appreciated!
Senior User
Joined: Feb 2004
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What the dealer calls the "actuator door" is what the post calls the "blend door".
The blend door post spells out the whole procedure. Remove the actuator, and make sure that it works. If it works - which it probably will - use a mirror to peek into the hole that the pin fits into. You should see a damaged hinge that looks pretty much like what is shown on the diagrams. Follow the procedure and you should have heat in no time.
My understanding is that Ford dealers will only replace the entire plenum assembly (which includes the blend door) to fix this problem. You can buy one yourself, but you'd have to rip the dash apart to install it...which is why the repair costs so much money. I've read posts from people who paid up to $1,200 for this repair. So you don't want to go this route. And a Chilton or Haynes manual won't help you here. A repair like this is usually out of the scope of manuals like those.
BTW, you won't find a manual just for a '94 Exploder. It'll be for the years 1991-1994, and will probably cover Rangers and Aerostars too.
Good luck!
The blend door post spells out the whole procedure. Remove the actuator, and make sure that it works. If it works - which it probably will - use a mirror to peek into the hole that the pin fits into. You should see a damaged hinge that looks pretty much like what is shown on the diagrams. Follow the procedure and you should have heat in no time.
My understanding is that Ford dealers will only replace the entire plenum assembly (which includes the blend door) to fix this problem. You can buy one yourself, but you'd have to rip the dash apart to install it...which is why the repair costs so much money. I've read posts from people who paid up to $1,200 for this repair. So you don't want to go this route. And a Chilton or Haynes manual won't help you here. A repair like this is usually out of the scope of manuals like those.
BTW, you won't find a manual just for a '94 Exploder. It'll be for the years 1991-1994, and will probably cover Rangers and Aerostars too.
Good luck!
