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Ford changed the plenum box in the Explorer in 2003 and the system is completely different from the previous models. However, the 03+ model years suffer from a similar blend door problem as the earlier models. The early models have a wear-out problem with the door breaking from constant stress of calibration. The newer model has a problem with the design of the system forcing the door out of alignment when it is moving. The stress is constant and results in a broken door sooner than the typical wear-out mechanism on the earlier models.
The technical explanation is a little involved without pictures and arrows. Check the Tech section on heatertreater.net for pictures and a full engineering evaluation of the system.
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