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2003 was a changeover year for Ford, so it's not clear if the system you are comparing to is the old or new. There are two different plenum boxes used by Ford on the Explorer in the year ranges you are questioning. Most likely both the 03 and 04 have the newer style box. Both the old and new designs have problems. Check the engineering report on the later model Explorer's on heatertreater.net. There are pictures of both systems that will help you identify which one you have and information on the fail modes and fix.

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Q: Are the 2003 explorer heater box in the same place as the 2004?
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