OT 2004 Explorer Heater Box Door

My father in law"s Explorer had a little rod break that controls a little door that directs air in the heater box to the windsheld (defroster) or floor or dash. He is able to get into the box enough to move the door manually, but is trying to secure it to get some defrosting.
According to the mechanic, the whole box needs to be replaced ($1,200.00; $70 for box & the rest is labor).

We plan to get in there to secure the rod to go half defrost/half dash air.

I thought I would post to see if there are any suggestions. He would take the replacement job on himseld (Retired), but he wants instructions on how to do it (to avoid screw ups) or just live with no control of where the air goes.
Thanks

In order to replace the box, you have to take the whole dash out, including the steering column, it is a real pain in the a$$. Good luck

Yes the whole dash has to come out. I replaced a heater core on a 2000 ranger a while back. What a pain!

FArmall Don,

I had that happen to my 1996 Explorer in Oct, 2007. Ford parts man told me "that happens in "06 & "07 models as they age". It was a little plastic door that controls the amount of heat going into the cabin, the door is attached to a rod that swivels back and forth, and the plastic door cracks and stops working even though the rod still moves. Ford guy said it would cost about $1100.00. After I picked myself off the floor I decided maybe we could just tough it out and go thru the winter without heat since we only drive that rig 6000 mi a yr for short runs to town.

Well, by late November we knew we were not that tough....we live in Wisconsin. Heat is survival.

I went to an auto repair shop run by a guy I trust. As I told him my problem he was already nodding his head and said "We have had several Explorers and Rangers in here with that problem...and most of them in the "96 and "97 range.

He told me the total parts/labor would be $900.00. I had no choice but to have it done since I can"t do that for several reasons. He fixed it (dash was removed) and now I have to drive the stupid thing another year or two with all that repair money invested in it.

That old Explorer has a 4L V6 engine with 115,000 mi. it runs like new, original plugs, a tranny that goes and goes, 4X4 that always works, original muffler, not a rattle anywhere, tight doors and awful mileage and a hard ride.
Wish I cold sell it, but at 6000 mi. per yr gas prices are not a big deal and it"s not worth much anyway. But when the motor or tranny ever breaks down that sonofagun is gone!

Don,

Oops, I had a heat problem. Sounds like you have an air direction problem. I had cold air go wherever I wanted it to go. If you have warm air it is great no matter where it goes!
LA in WI

Research this link,,, they mite have a repair,,, Folks at the AC forums say they use the door but not the hacked up technique to replace it,,, they pull the complete box,,, they say the door is the ticket,,, I don't think you can git the door from Ford,,, only a complete unit
Heater Treater

I had to change the blend door in my 99 Navigator. Ford dealer said it would be about $1000 to change a $27 dollar cheap plastic blend door. I did it myself. Job was horrible but I got it done in a couple partial days. Had to take out the steering column, both air bags, console and the complete dash. My cousins have a 2004 f-150 with the same problem and my friends 99 chevy z 71 is doing it. All the companies have problems because they all buy similar parts to build the cars. Very bad design by some engineers that shouldn't have jobs anymore. The doors should have been made of aluminum and there would be no issue for the life of the truck. Now there are millions of dollars in repair costs due to poor planning.

Be glad it is repairable.
I have been told that beginning with the 2010 models of big 3 vehicles any repairs that would require removal of dash, steering column, or any air bag will no longer be allowed by federal mandate. The vehicle will be considered totaled and have to be junked.
I was told this by the district manager of GM.