Heater Stuck on Hottest Setting Due to Broken Heater Blend Door on Ford Explorer Sport Trac

Problem Description and Possible Solution

A failed heater blend door or actuator can cause the temperature control for the HVAC system to stop working. A clicking sound from the dash area would commonly indicate an actuator fault. If the heater gets stuck on the hottest setting, the heater blend door may be broken requiring replacement of the heater box to repair the issue.

Problem Data
RepairPal Verified
Average mileage: 93,250 (42,000–199,000)
8 model years affected: 2002, 2003, 2004, 2005, more2007, 2008, 2009, 2010
39 people reported this problem
Viewing 1 - 18 of 18 comments
clicking sound then nothing but cold air, how can I fix it myself
blend door messed up. stuck on cool air.
After running for a few minutes the passenger side switches to heat and will not go back to cool. If I turn off the engine it may work again.
no heat clicking sound.
I had a problem with the heater box blend door also. I also had a clicking sound . There is a small servo that moves it back and forth the gear was stripped I pulled one at the junk yard and replaced it. I actually only changed the gear itself.
same clicking sound and stuck on cold air . need to know how to remove dash assembly to access heater blend box.
Heater stuck in hottest setting,only thing i can do is cut it off when it gets hot.
Heat works, no cool air.
Blend door makes clicking sound when turning knob to heat.

Nothing yet as I still have heat/cool air, defrost capabilities. I am very careful with turning the knobs.
Haven't had it repaired yet.
started out as clicking problem and now is stuck on heating.
Vehicle wasn't warming the cabin... warped heating box/flap.
Cost me $475.00 to replace... mainly labor because of how time consuming it was to reach/remove warped part.
This is the second time it has broken since I had my explorer...in the shop now for an estimate
Cost me 400.00 to fix
No heat clicking sound blend door problem
clicking sound started then before I had time to investigate the position 1 and 2 on the HVAC controls do not work anymore.
Passenger side stuck on hot.
hasn't been fixed yet dealer wants 1,000 to repair