There is a door that opens and closes directly behind your glove box. If you hear no blower motor difference when switching from regular AC to MAX AC and the air flow from vents is not coming out as hard as it should but you do get cold air this is your problem. to fix it simply remove the bolts around the casing which is the square plastic box behind the glove compartment above the blower motor plastic housing. you will not be able to remove the casing but you will be able to pry it open. Use some needle nose pliers and grab the broken door and pull it out. There is a repair kit but it requires taking the entire dash out and its not worth the time unless you really want to spend 12 hrs just so you can draw outside air. Also if you really would prefer to never get any fresh air and only circulate air already inside the vehicle you can get underneath the hood and remove the cowling and place tape over the-opening from which the vehicle gets fresh air.

(OPTIONAL) PS as a side note, people that do prefer to remove the door instead of repair it also will often use a dremel tool and cut out the lower portion of that box so that they may insert a air filter (this vehicle is one that does not have a cabin filter) so they can get truly clean air. You just have to find one that fits if you want to go this far with it. Not necessary but still good to do if you care about the air quality.

I THINK ITS AWFUL FORD MOTOR COMPANY THATS BUILT ITS WEALTH IN THE UNITED STATES , WOULD PRODUCE AND SELL TO THE PUBLIC WHAT I BELIEVE TO BE A KNOWN ENGINEERING FAULT WITH THE HEAT/AC BLENDER DOOR DESIGN. PLEASE ! AND I ALSO THINK THEY ENJOY THE MONEY GAINS FROM THE EXPENSIVE REPAIRS. IT TRULY PRESENTS REAL HAZARDS TO THE OPERATOR/PASSENGERS BUT YET FORD WILL NOT RECALL THESE VEHICLES. I DO PLAN TO TAKE LYING DOWN AND ENCOURAGE ANYONE WHO HAS OR CURRENTLY HAVING THIS PROBLEM TO CONTACT YOUR LOCAL BETTER BUSINESS CHAMBER OF COMMERCE OR GOVERNMENT REPRESENTATION

First off the blend door actuator went out on my '02 explorer. No big deal bought a new one easy to replace not too bad. A couple of weeks later found that the blend door was stripped too. No big deal either right, I'm pretty car savvy. YEAH RIGHT!! So I buy what I thought to be the part I needed. A buddy and I started to check it out with no luck as to where or how to get at it. After several attempts I figured, well it's almost summer no need to worry right now. I'll do it over the summer. It sat in my garage until now. Yeah, it's winter and it doesn't work. We did figure out how to do it finally after 8 hours of messing with it. Got the door out and guess what TOTALLY FREAKIN DIFFERENT FROM THE ONE I BOUGHT A YEAR AGO! I said no big deal maybe we have the wrong one. Went to every parts house out there they all carry the same repair kit claiming it is for my vehicle. Bull it's too small for the compartment and it wouldn't work anyway with the actuator. So I have no blend door in it now and I guess I will search until I find a solution or I manufacture my own. Yeah this is some total bull $h!t.