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To DIY you're going to have to pull the dash. If you're going to take it to shop, be prepared to pay for 6+ hours of labor, quite expensive.

No NO NO do not pull the dash. On my 1998 it was outside the blend box. It's bad because of bad soldering in the motor circuit board, easy fix once you pull it. Yes the shops want 6hrs labor. My blend door shaft broke and I had to replace it. I found the bad soldering problem after fixing the door.

Blenddoor.com has a fix for that door problem...........

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Q: Cost of labor repairing blend door actuator or how do you repair it yourself on a 2004 Mercury Mountaineer?
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