I have that blend door problem and used that great write up at http://www.blenddoorfix.netfirms.com/
Anyways, i got it to work, but only a couple of times. It keeps breaking whatever I am sticking threw the hole when I turn it back to heat, thats some strong force !! I tried a cut nail and cut a drill bit. What did yall use to fix this?

 

I have an Explorer EATC blend door actuator (and EATC) and it's not been a problem.

 

?Thats how you fixed it? I wouldnt want to take the dash out if I can get this to work.

 

I didn't. Just the actuator was replace and you've already had yours out.

Take a look at my Cardomain on pages 13-18. It's a how-to on putting EATC in your truck and on one page I cover the actuator. Not sure there's much there for you but you can see I take it out and replace it without taking the dash apart -- even taking out the screws. It appears your newer one snaps in, but some older models you have to use the screws.

I have never taken my dash apart and like you I'd like to never have to!

 

Thanks a hec of alot! I will try this NewYears

 

Ah its not as bad as it seems...You just need to figure out where Ford hid all the nuts and bolts. I had to pull mine last year for a new heater core. A couple beers, a pack of smokes, and a few words and it was done.

 

lol! I won't ask about the words...I know pulling it's not terrible -- I'm just terribly lazy, lol...

 

I figured it out, I had to re-tap a hole slightly angled to get it to fit right back in the hole. Thought I would pass it on for when it happens to another ranger.