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You have a faulty temperature blend door actuator located directly behind the radio. Remove the radio and remove the blend door actuator held to the heater case with three 8mm screws, and replace it.
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Your heater blend door actuator has broken some teeth off internally. This is a VERY common problem in explorers. I have replaced two of them. Go to the Ford dealer an get part number yl5z-19e616-aa. Remove the left rear inside trim panel and this will allow you to access it. It takes about 30 minutes to replace.
the temp. motor is on the passenger side behind the glove box. remove glove box,look left toward center of car.the temp motor has three screws and is mounted on heater box.
Remove the dash assembly to gain access to the blend door actuator.
Unfortunally you need to remove the entire dash assembly in order to gain access the the blend actuator. Consider replacing the heater core while your in there only because the amount of work involved to do it later if it should leak.
Behind glovebox in heater housing...remove glovebox and picture will form....
Remove glove box liner. Blend door is located in the heater/evaporator housing. There are several kits available to repair blend door shafts as well as troubleshoot system.
The heater flap, or blend door, is difficult to replace with OEM parts supplied from Ford. There is an aftermarket kit that makes the job and cost significantly easier at heatertreater.net or on the Ebay listing.
You have to remove the dash completely. Once you have the dash removed then you have to un hook the coolant lines. Label and unhook all the vacuum lines. Then you have to remove the plastic center piece that has the blend doors etc. It is held together by a bunch of metal clips. You have to remove the clips then it splits in two. Then you can remove the heater core and replace it. Make sure that that the new foam creates a good seal. Then put it all back together. It takes a good amount of time.
The problem is the blend door, not the heater core. Any mechanic worth anything should have checked and replaced the blend doors while it was apart to replace the heater core. Check heatertreater.net for diagnostic information and some real help.
If by "heater box" you're referring to the heater core, we've got you covered with the "Related Questions" below.Be sure to review the questions regarding the blend door and blend door actuator motor - other very popular heating/cooling parts in the Windstar