Just came across this. Napa, Rockauto and others have a replacement blend door about $11.00 US and this link explains how to replace without removing the Plenum.
http://proacshops.com/artman/publish/article_22.shtml

Scucci

 

http://www.blenddoorfix.netfirms.com/

 

Steve, that is the way to do it if you have it fail and are lucky enough that the part did not get obliterated to the point of not engaging anything. In my case this approach was a no go, so I used the other approach, replace the door.

Unlike the first post shown here I opted for a slightly more destructive method as descibed in TalonDad's Plan-B process... a new door and a hole in the bottom of the plenum to replace it. See this post to read about it Had I not been screwing around in the cold and the dark it would have taken me a very short time to replace it.

 

Hi guys, I haven't been here for a while. Glad to hear this info has been helpful. The replacement blend door part number info is helpful to me also.. Thanks. After 2 years, my repaired blend door is still working, but if it should fail again, I'll pop in a new one.

 

Hey Scucci!

Hows your blend door working out for ya? I have the same problem here and wondering what to do and if i should use the same method you did.... Let me know how you mad out!

Thanks!!!

 

I haven't had the blend door problem yet. I found the article and thought it might help some people here.

Scucci

 

Replaced my blend door today with a new one from NAPA a pain in the a** but with a some time and no one to bother you it will work fine once installed. Any questions i can help ya out if someone needs it.

Good luck!!!