There is a blend door that is know to give problems. Sometimes the blend door itself will break but there is also a blend door actuator that can fail. The blend door actuator is located behind the dash...kinda behind the temperature control knob and is a pretty easy fix if you're able to hang upside down under your dash for about 20 minutes. The actuator costs around $50.
I've never replaced the blend door itself, but have read up on it when I thought that might be the problem. Let's just say the part is cheaper but clear your weekend. I think step one of building a Taurus is the blend door....it's buried in there.
Hope this helps.
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