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Answered 2015-07-15 18:50:30
"Blend door stuck and clicks on your 2004 Ford Explorer?" FIRST BUY OEM BLEND DOOR MOTOR $57.00 + UPTOOLS NEEDED :

PANEL TOOL OR FLAT BLADE SCREWDRIVER ,1/4 SOCETS 7 & 8MM

....1/4 HANDLE...1/4 SMALL EXTENTION...1/4 RATCHET

NO NEED TO REMOVE WHOLE DASHBOARD!!!REMOVE TWO7MM SCREWS FROM THE BOTTOM OF STEERING PANEL & PRY AND REMOVE PANEL.

NEXT REMOVE TWO 7MM SCREWS ON BLACK PLASTIC STRIP THAT YOU SEE AFTER REMOVING STEERING PANEL....PRY THIS STRIP OF PLASTIC OUT JUST A LITTLE AND CUT IN THE MIDDLE .

NEXT REMOVE TWO 7MM SCREWS FROM AROUND TOP OF INSTRUMENT PANEL (BY GAUGES ) PRY PANEL STARTING FROM AROUND VENT ON LEFT BY DRIVERS DOOR ""THIS PANEL WILL STAY IN PLACE LOOSE... NO NEED TO REMOVE!""

NEXT YOU WILL SEE 0NE 7MM SCREW BY GEAR SELECTOR AREA.. BEHIND THE LOOSE PANEL REMOVE THIS SCREW.. ALSO IN SAME AREA BUT LOWER THERE IS ONE 7MM SCREW THAT NEEDS TO BE REMOVED THAT HOLDS LOWER DASH PAD ITS FOUND BEHIND LOWER CORNER OF DASH PAD.( LOWER DASH PAD GAS PEDAL AREA )

"DON'T"!!! REMOVE THE FOUR 10MM BOLTS!!!! IN SAME AREA

NEXT REMOVE RADIO /AC CONTROL TRIM WITH THIN SCREW DRIVER OR PANEL TOOL IT HELD IN BY SIX CLIPS...NO NEED TO DISCONNET ANYTHING IT WILL STAY THERE HANGING!!

NEXT REMOVE TWO CENTER CONSOLE LOWER LARGE PLASTIC CLIPS BY FLOOR MATS. NEXT UNDER SQUARE BLACK RUBBER AT CENTER CONSOLE REMOVE ONE SILVER SCREW. MOVE SEATS FOWARD AND REMOVE TWO 8MM SCREWS FROM SIDES OF CENTER CONSOLE FROM BACK SEAT.

PRY CUP PANEL SECTION THAT WAS HELD DOWN BY SILVER SCREW ...PRY UP TOP HALF OF CONSOLE STARTING FROM SECTION WHERE ARMREST DOOR IS.. DISCONNECT LIGHTER PLUG AND REMOVE PANEL .

NOW YOU WILL SEE SIX SCREWS STARTING FROM BELOW RADIO TRIM WORKING BACK TO ARMREST DOOR .REMOVE ALL SIX..THESE HOLD THE BOTTOM PORTION OF THE CONSOLE ALSO DISCONNET ONE BLACK PLUG AND PULL ALL THE WIRES CLIPPED DOWN...PULL BOTTOM PORTION OF CONSOLE TO BACK SEAT.

PULL LOWER DASH PAD GIVE A NICE TUG.. IT SHOULD MOVE OUT A LITTLE ..DID YOU REMEMBER ONE SCREW BEHIND CORNER DASH..!.STARTING FROM AREA BY GAS PEDAL LOOK UP IN THIS AREA YOU WILL HAVE ENOUGH ROOM TO GET A LONG EXTENTION WITH AN 8MM SOCKET TO REMOVE 3 SCREWS HOLDING MOTOR TO BLACK PLASTIC SECTION..

REMOVE SCREWS DISCONNECT SMALL BLACK PLUG AND PULL MOTOR FROM SOCKET GOING TOWARD DRIVERS DOOR DIRECTION. ALIGN NEW MOTOR SHAFT WITH SOCKET

TIP.......IF NEED BE..... YOU COULD PLUG MOTOR HARNESS INTO NEW MOTOR THEN TURN IGNITION ON AND MOVE HEATER/AC CONTROLS TO GET THE SHAFT LINED UP..DONT MOVE ANY OTHER WAY!!!!!!NOW PUT SHAFT INTO SOCKET MAKE SURE YOU CONNECTED THE PLUG IF YOU HAVEN'T ALREADY!! INSTALL 8MM SCREWS AND TRY IT OUT YOU SHOULD HAVE HEAT NOW NOW INSTALL EVERTHING BACK IN REVERSE ORDERTOTAL TIME 45 MINUTESYOU JUST SAVED $350-$500 IN DEALER PRICES!!!DEALER 2.5 HOUR JOB! PLUS PART
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