2004 Ford Explorer repair bend door

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

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!!!
https://www.2carpros.com/articles/mitchell1eautorepair-car-repair-manuals
Good Luck;
Rick

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