Two problems related to blower have been reported for the 2004 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford Explorer based on all problems reported for the 2004 Explorer.
The heaters blending door is broken so the air flow will not be redirected. It is currently in the dashboard setting and I am unable to redirect air flow to the defroster. The dealership wanted $1500 to replace the heater because the broken part is molded onto the heating element and they need to remove the entire dashboard. I searched for similar complaints, and Fords vehicles have a long history of blending door problems. Not being able to redirect the air flow is extremely dangerous, especially during the winter months.
The contact owns a 2004 Ford Explorer. The contact stated that the blower that recirculates air has failed. As a result, fumes and anti-freeze consume the passenger compartment of the vehicle. The contact suffers from numerous headaches and sleepiness. She consulted with a medical physician and was informed that the amount of fumes being congested poses a significant safety risk. The dealer stated that the flapper for the blower needed to be replaced at the cost of $300. The vehicle has not been repaired. The failure mileage was 56,000 and current mileage was 86,000. Updated 3/24/09 updated 03/27/09.