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Thanks Quintin,
Am in the middle to trying to get my Blend Door replaced. You're post is helping a lot. Still a lot of learn as I go on items in my '99 F150, but it would have been a nightmare without your help.

The vid at the site for the cut and fix(altenate) method was a help, in that, I used it to get the vent off the bottom and remove the actuator to see if I got bits and pieces of my blend door shaft. Sure enough.. what was left of the shaft fell out in my hand. Not one to butcher up a car when it is just labor needed to do it right, I jumped off into it. Only working in cool evenings, 3 days and dash about to come out. But, I have learned that many of the screws I took out were not required and reinstalling the Dash will go much quicker.

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