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Q: Is it possible to replace the heater blend door witout removing the dash assy? on 1997 Ford Explorer

My 1997 Ford Explorer has a malfunctioning heater hot/cold blend door (Socket the actuator attaches to is broke) and I have purchased the Dorman replacement door, however I do not have the time necessary to take the vehicle out of commission to r&r the whole dash assembly just to replace the door. Is it possible to replace the door from under the bottom of the HVAC box using a rotary cutting tool? Is it necessary to remove the dash and if it is unavoidable where do I find the instructions to remove the dash assembly to access the HVAC box?
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No its not. I just cut an access hole in the bottom of the HVAC plenum and replaced it this PM. I used the cover plate provided with the Dorman repair kit to cover the hole. If you do this dont get carried away with the dremmel tool because like I did you will have to seal the oversized hole up with silicone sealer. The plate provided will need to be modified to fit the underside of the plenum, but it can be done. Saved myself a days worth of work not removing the whole dash. Nothing's impossible with a little patience and observation of the plenum. Just stay away from the rib that locates the heater core in the housing.
Well. . . I too went to Trade School for this kind of stuff, but on a customer's vehicle I would have probably offered them the opportunity to choose how this would be fixed. I am also willing to take the time to look at the problem at hand and try to come up with an easier way to do the job. Especially if it's my own vehicle where I dont worry about "doing it right." I'm no ASE Master tech, but then again I could be if any of the shops I worked in would have required it and paid accordingly.
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