[wilky448525]

I took the dash apart today on my 2003 Expedition and removed the acuator. I took it apart and found broken plastic gears inside. Verified blend door functioning properly and put it all back together. I am glad I did not have to take the plenum apart because the way Ford made it I would have had to remove the whole thing and disconnect the heatyer core lines and evaporator lines. Took me about 14 hours start to finish but took breaks for lunch and dinner and had to run to the parts store. Thanks for the pictures. Although they did not match it gave me a good idea what to look for and where.