Aussiblue

Also see Quick and Easy Blend Door Replacement Tutorial - Ford Explorer Ranger Enthusiasts Serious Explorations
and Free Ford Blend Door Fix this covers your Expedition.
and WikiAnswers - How do you repair the blend door in the heater on a 2004 Ford Explorer
Blend door replacement with pictures - F150online Forums
Google Image Result for http://www.markviii.org/LOD2/blend_door_repair/blend_door_actuator.jpg
http://www.heatertreater.net/Final%2...fo.htm#History

Note SAABs and Dodge/Chrysler/Jeeep have similar blend door issues so it's not just a Ford thing

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Regards Blue