Reread all the posts today and have some comments that may help ("may" being the operative word here.
Alternator. I noted in both of North44's cases his battery was three or more years old. Just replaced the alternator in a friend's 4-cyl last week...along with the four year old battery Is it possible the alternator is not robust enough to handle a weak battery? Check your battery. If it's weak replace it. Repeatedly asking your alternator to charge a weak battery can cause failure, particularly if the alternator is not heavy duty enough.
Blend Door. Google it in the Explorer forums. The servo is on the top of the heater plentum and the dash must be removed to get at it. There is a little piece of plastic that breaks. This can be fixed from the bottom and involves some "cut and paste." Never done it, but it was an issue some time ago.
Hub failure (late models). First clue may be anti-lock brake light. The bearing fails and misaligns the anti-lock sensor. Had it happen on my '00 Explorer. Tech said there is no telling when failure will occur. Sometimes new, sometimes never.
Tailgate handle. Look on e-bay and buy a metal one. Then keep your mechanism well lubed (chain lube is great for this). Also push in the tailgate as you open. Breakage is caused by the latch dragging against the receiver.
Transfer case servo motor. The motor drives a worm gear with finger contacts on the cover. Before replacing clean them up. Use a pencil eraser to "rough them up" a little. If that doesn't work, take the motor apart and clean the armature. They are not made to be taken apart, but with a little persuasion you can do it. I did it on my '92 Explorer and never had a problem after that.
Locks. Early 2000 - ?? models (the ones with 9-10-11? tumblers in the lock -look at your key to see) use the first few tumblers to work the ignition and the rear tumblers to work the door (or the other way around) - hence the long key. If you don't use the key in the lock once in awhile the lock can get rust and fail just when you need it most. This is also true because the back of the lock mechanism is "open" to the elements. Before you have to use it, spray some penatrating oil and work the lock if it's stuck. Otherwise use it once in a while for grins.
Thermostat. Watch your gauge closely. Over time has it crept downwards on the scale? The original Ford units were made by Bosch. These had a habit of - over time - failing to close, allowing the engine to run cooler than it should. Two problems from this. Heater doesn't work worth a hoot, and the engine does not get out of the cold cycle loop causing your economy to drop by 2-3 MPG.
Can't help with any thing else. As I said in a previous post, my '05 is doing very well so far. Very happy. Do wish the seats were better and had more support. At 6'2" w/out cruise control I wouldn't be able to drive it the long distances I do.
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