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To install the Blend Door Actuator in 2004 Ford Explorer

Tools needed:

7 mm socket

8 mm socket

10 mm socket

Socket wrench with extension bar

Long stem 8 mm box wrench

Large flathead Screw drive

You will need to remove all the following parts. Please be careful while you are removing these parts for wires may be attached and you do not want to break anything.

1. Remove the counsel; first remove the rubber pallets inside the cup holders then remove the screws that will be exposed. Use the screw driver to gently pry the cup holder saddle from the counsel. Be aware that there is a wire connected to the cigarette lighter.

2. Remove all screws holding the armrest in place. There are also two plugs at the foot of the armrest one on the driver side and one on the passenger side. Use the screw driver to gently pry this plugs out (they pull out and push in). Once you have removed all of this, lift the armrest up and pull back you remove it completely.

3. Using the screw driver again, gently pry the dash cover from around the radio and temperature controls. This snaps in and out. Once it is out, disconnect all wiring.

4. Now remove the radio.

5. From under the steering column, remove, remove the undercover panel.

6. Now remove the top panel. There is a leather skirt connected to the steering column that snaps to the steering column that also needs to be removed. You may have to put the gear shift in D3 to remove this piece. There are also wires attached so you have to be gentle with this piece. Once you have this out, disconnect the wires and set aside.

7. Now you ant to remove the control panel. You only want to loosen it then move it to the side. DO NOT try to take it out completely. There is a fine cable attached that cannot be removed that you do not want to break. Once the panel is loose, you can move it to he side. The opening it creates will give you clear access to the Blend Door Actuator.

8. Back down on the driver side, remove the black air duck.

9. Here is a tricky maneuver: there is a 7mm screw located in a tight spot under the steering column where the panel that is blocking the view of the Blend Door Actuator meets the dashboard. You cannot see the screw but you can feel it and it is easily accessible with a 7mm socket and wrench. Once this is removed, it will allow you enough pull to remove the Blend Door Actuator once it is lessened. This eliminates any cutting to the dash.

10. Now you are ready to start the process to remove the Blend Door Actuator. Using you 8mm box wrenches remove the three screws holding it in place. You may be able to use your socket wrench on one of them. Once you have removed the three screws, the Bend Door Actuator is ready to come out. Since there is a long stem on the Actuator, there is not enough room for it to back out, so you will have to pull the panel the we spoke of earlier just a little to give it room to pull completely out.

11. Disengage the wire from the Actuator (you can do this before you take it out as well)

12. Installing the new Actuator is also tricky; it has to line up with the gear inside the airflow system. It takes some patience but it can be done. You have access through the opening by the control panel and from under the dash. Take your time to line up the gear. It takes a little pushing to get it to go in place.

This is a tedious job and will take anywhere from four to six hours if you are doing this for the first time. Be patient and take small breaks to relax your muscles. You will not need to remove the glove box. However, if the bend door is open, you can access it through the glove box to close it which will help with installation of the new Actuator. The closed position is when the bend door towards the seat. You cannot see it you can only feel the position of the bend door.

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Q: How do you replace a blend door actuator for a 2004 Ford Explorer?
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