Had some time and researched the problem and found that the Blend Door is a common problem with Ranger/Explorer. I see where the actuator has a 90 degree swing to open the door inside the heater box BUT the area is more like 65 degrees. So the door is under constant pressure when fully closed causing the shaft to break at the top. There are numerous places that can be searched on this subject. I took a dremmel and opened up the heater box from the bottom and removed the door and put it back together with pins and some epoxy. Works great now and saved myself over $1000. The stealer wanted to take the complete dash out and remove the entire heater/AC unit to do a replacement of the heater box door. By doing a hole in the bottom there is no need to tear the dash apart. You can epoxy the heater box back together and being on the bottom, you can't notice it unless your on the floor looking up. NAPA also sells new heater box doors for $10.99 plus shipping. Very simple fix and saved a crap load of money. Do some research on Google for Ford Ranger Blend Door repairs and you'll be astounded as to what you can do. Hey the $$ is better in my pocket than the stealership.
