Reddit mentions: The best automotive heater blend door levers

The manual I have is just junk, but I did a quick search online and the actuator is pretty darn easy to replace. This video is pretty straightforward. The part runs about twenty bucks and I believe the only tools you'll need are a ratchet, short extension, and 7mm socket. This actuator has pretty good reviews.

It could be worse. You could have a leaking a/c evaporator. That was what I've been dealing with the last two weekends. A black Avy with dark pewter leather is just not okay without a/c.

I have an update on my own blend door problem. Because I'm a glutton for punishment I went ahead and bought the Dorman replacement that I mentioned in my other comment and did it myself instead of taking it to Ford. I can confirm that the Dorman part is significantly heavier, physically thicker and higher quality than the OEM unit. The gear set is in a slightly different arrangement and the gears themselves are more robust. I can also confirm the overall shitty quality of the OEM part.

The install wasn't quite a nightmare, but it was challenging. I used this video as reference though I didn't have to take the driver's seat out. I also had this handy mini ratchet which was absolutely perfect for the job along with a T20 bit. Now the tricky part which I wasn't quite sure of going in: I switched the car on and turned off the HVAC assuming that doing so would put the actuator in some sort of parked position. This probably isn't necessary since it likely goes back to the same position when the car is turned off. Anyway, after removing the OEM blend door I noted which position the output shaft was in. There's a little arrow on the casing that part of the gear lined up with. The new unit's output shaft wasn't in the same orientation. So, I plugged the Dorman unit in but didn't install it, turned the car on and switched the HVAC on and off to put the new unit in the same position as the OEM one. After that I noticed the output shaft still wasn't in the correct orientation. So, I had to open it up and take out one of the drive gears so I could reorient the output shaft. Once I did this the new unit slid into position pretty easily and I tested it out and BAM, no noise and the climate control works as expected. Now to see if this one lasts longer than 13,000 miles but after seeing the two parts together I really think it will. Hope this helps someone!

Edit: So I've got everything in one place for people stumbling across this here's the link to the Dorman part. It is Dorman 604-400 Air Door Actuator replacing OE part BE8Z19E616B

You probably could do so easily...

https://youtu.be/vyDNLd9o-20 shows you where it is and what it looks like.

It seems that the actuator itself is only $25-40. By the time you get in and change the blend door position, you might as well fix it right and button it up. You'd have to remove the old actuator to move the blend door.

https://smile.amazon.com/APDTY-Temperature-2001-2006-97159-2D000-971592D000/dp/B00CMXS8MK/ref=sr_1_5?keywords=2006+hyundai+blend+door+actuator&qid=1572653295&sr=8-5

https://www.ebay.com/itm/New-AC-door-Actuator-fits-97159-2D000-fits-Hyundai-Elantra-604-303/153030410302

But be aware, it looks like there are two actuators on that HVAC unit, you can see the other one is mounted higher up on that same side. The upper one is used to select vent/heat/defrost, the lower one is temperature.

If you do the repair, make sure that you fit the pin in the actuator into the appropriate place on the actuated thing during installation. Move the temperature dial or the blend door position to make it fit.

Make sure you get the Dorman brand ones or you will be replacing them again. This is a stronger part that fixed the issues with the OE ones. https://www.amazon.com/Dorman-604-400-Air-Door-Actuator/dp/B01ID3WOM2

https://m.youtube.com/watch?v=ucOTZAg27lo

http://www.amazon.com/Dorman-604-213-Air-Door-Actuator/dp/B004IYWGQU

Behind the panel above the passenger rear tire area inside the vehicle is your rear air controls. The blend door mechanism inside that panel has broken and is stripped. The thumping you hear is it turning and slipping. Super easy fix, takes about 20 minutes.

Yep, I did the exact same thing for the same reason, used a dremel and gorilla tape. Just be careful you don't nick the heater core. There's also a kit you can pick up with new doors and better rods - https://www.amazon.com/Red-Hound-Auto-Compatible-Temperature/dp/B06WP877JG. They've gotten way cheaper in the last few years, I've heard of people doing the replacement from a side cut old behind the glovey, but I haven't done it myself..

Mine was doing the exact same thing and I ordered this from amazon and watched a couple of YouTube videos on how to change it. Cost me $15 and about an hour of my time and it’s been fine ever since. I have a 2011 F150 XLT, I don’t know what year yours is so it may be a different part number.

Edit: I also noticed with mine that when I would try to change the temperature it wouldn’t change at all, it was stuck on one setting.

Blend door actuator. Get it replaced under warranty and do it again later or buy the Dorman unit. https://www.amazon.com/Dorman-604-400-Air-Door-Actuator/dp/B01ID3WOM2

Mine was one of the others that's far easier to get to. There are videos on youtube on how to remove the dash bezel and cluster, not that hard but takes some time. There are reviews of the one I bought failing in 3 months but mines been going since last July with no issues.

https://www.amazon.com/gp/product/B00HRSTTMI/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1