Do you get a clicking sound when you turn the temp selector to warmer settings? If yes - it may be the blend door - lots of posts on this subject right now.
If not then maybe this is your problem - the vent door to the dash vents may not be working properly - check out this photo to reference the Panel/Defrost Door vacuum motor:
http://www.explorerforum.com/forums/showpost.php?p=1771631&postcount=10
There is an arm that attaches this motor to a lever on the door to open and close it for airflow through the dash.
Steve[/QUOTE
I have a 04 explorer that doing the same thing. I took it to my uncle who retired from Norfolk's ford plant after33 years told me it's the acuator thats causing the noise. Also, there isn't any heat coming in. It looks like from what I've been reading here sounds like a defected part. I'll be caliing for motor company on Monday and inform them of the prblems everyone is having pertaining to the heat.