Step-by-step instructions to remove the dash to replace the blend door on 1995 through 2001 Ford Explorer all models?

Answer 1

This is a brief description of how to access the Blend Door. Plan at least 8 hours. My first time took 2 weekends. I highly recommend finding a Blend Door kit on eBay for about $25. I found that many other descriptions (including the manuals) made me remove lots of items that did not need to be (radio-cd-player). Here are the essentials. *1: Disconnect Battery Terminals *2: Remove the center console A: Pull the front storage shelves (light pressure) B: Pull the cup holders C: Loosen the screw that holds the wiring harness until the harness is free D: Remove the two bolts from the dash E: Remove the two bolts under the cup holders F: Pull the center console straight back (is held under rear by open ended clip) apply as much pressure as needed. *3: Remove the steering wheel column A: Remove the emergency brake lever holder B: Remove the hood latch lever holder C: Remove any remaining bolts on the bottom of this cover D: Pull this cover straight back to release from pressure pins E: Remove 4 bolts holding steering column and collar F: Remove bolt from steering column u-joint G: Pull steering column off - lay on front seat *4: Remove the dash-board A: Remove the dash vent by pulling straight up B: Remove the small screws across the front that are now exposed C: Remove the kick panels from both sides of the dash D: Remove the passenger air-bag (gain access through the glove-box) E: Disconnect all wiring harnesses on passenger side behind kick pannel F: Get a helper G: Remove the 5 brass bolts (two on left, two in the middle, one on right) H: Remove the dash from the firewall I: Pull passenger side back out of the way to gain access to plenum *5: Install Blend Door A: Cut hole in plenum using eBay kit B: Install new eBay Blend Door kit *6: Reassemble