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It is either a broken blend door, or a broken actuator motor. Typically to fix this problem, a mechanic will disassemble the entire dash, and replace the plenum box. Unfortunately this is an expensive fix because it is labor and parts intensive. There is a DIY solution called heatertreater. They provide instructions on how to access the blend door by removing the glove box, and replacing the blend door without removing the dash and plenum assembly. Broken blend doors are a common problem among Ford explorers, and most heating and A/C issues in late model Ford explorers are directly caused by a malfunctioning blend door.

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Q: 2004 Ford Explorer heater problems clikcing noise?
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I have a 2004 Ford Explorer and the heat does not work, but when i try to turn the control valve to heat it makes a clicking noise. How do i fix it?


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