I have an 02' Eddie Baurer with the same issues as described in the thread title.
I paid $400 for a reputable shop to diagnose. They replaced a thermostat, didn't do anything. They observed the blend door actuators moving, also when the temp is changed on the head unit, the air will go from cool 60* to warm when put on 90* and reverse. Their next diagnosis was to replace both front and rear heater cores for $1000. I was skeptical because I was wondering how both Heatercores could go bad at the same time, while I don't think that it is impossible as they are most likely the same units, use the same coolant, and are the same age. I opted out and tried to first flush the heatercores with some Prestone Coolant flush.
To do this I completely drained all of the coolant. I bypassed the surge tank so that the flush would go into the heater core first at maximum strength, fearing it might cause a leak because I used the Prestone on my Grandfather's Ford Motorhome and the heatercore began leaking, but he later told me he had dumped some Alumseal in it to stop the heatercore leak, so most likely the flush just ate that up when I used it on his motor home. No leaks yet after using in my Expy.
To flush I took off the heatercore inlet tube coming off the water pump/block location. As I poured the flush down the tube it did overflow a bit, but would slowly drain down, indicative of possibly a blocked restrictor. I did not know there was a restrictor in the line until reading on this forum, as others I thought it was primarily a hard piece of line to keep the rigidity in the inlet hose as it routes upwards going towards the T.
The inlet T to the heatercores get to hot to touch after the temps are up. The return T never gets as hot as the inlet. I would expect a slight difference as with the fans on maximum blowing across the heatercores it should technically cool the return temps some as it is nothing more than a intercooler in operation like for any air to water intercooler, turbo etc. But the temp is luke warm at best and I can easily hold onto the line with my hand for as long as I want.
Too me that is indicative of a flow restriction. Which could mean:
1.) partially clogged heatercores.
2.) partially plugged restrictor.
3.) water pump (read where electrolysis can eat the impellers over time).
4.) all the above.
I will start with the easiest and cheapest to replace first, which will be to bypass the restrictor to see if the improved flow without it in place results in the return heatercore T getting hotter, if it does I will know some flow improvement helped. Once the restrictor is checked, I will replace the waterpump as it is fairly inexpensive for both time and parts (especially since I will do it myself). If that doesn't work, I will replace the rear heatercore as it is easier to get to than the front heatercore, if the return T rear line gets hotter than the front heatercore return at the T, this will confirm the heatercore is an issue as a flow restriction.
Then I will have to tear apart the front dash to replace the heatercore or pay somebody else to do it so I dont have to deal with the frustration. But that is unlikely as the Expy is only worth about $6,000, and to pay somebody 1/6 of the cost to fix the heater is something I doubt I will do.
Because I have done many searches regarding this issue, and don't often find that people return to threads to post their results. I will be sure to report my findings. It's hard for me to believe that nobody including Ford hasn't been able to report on what the fix was/is. I hate throwing money at old vehicles to chase unclear diagnosis. So hopefully what I outlined will plot the course for fixing this issue with the heat and I can report back successful results to help others with this issue.