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The very early 2011's have issues with the blend door and Ford had a bulletin out to replace the whole plenum assembly. Yes the dash has to come out. Been there and done that.
Wow, Ford had blend door problems going all the way back to 1985 or earlier. You'd think they would learn their problem and use a hinge rather than a crimped piece of plastic.
No console removal will get to it. As for the blend door problem it's not the door but the design of the plenum, that's why they recommended replacement. We installed a used one from a 2014 to correct our issue.
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