"I will share the trick I used to get the blend door in to give the next person another option. You are right that getting the two ends of the door into the corresponding holes is a nightmare (I used nightmare as I don't think I can cuss on this site). So I cut a hole on the face of the plenum (right behind the golve box in the top left quadrant). When you look into the hole you see that the plenum is actually a two piece box glued/welded together on the outside. Inside is a verticle divider in the middle runing right about where the top and bottom holes for the blend door are. Stick a regular screw driver into the spot where the two halfs of this divider meet, twist just a little, and you have enough room to get the blend door into the correct spots. Once you let go you have a fit as good as the OEM"