Freed up mode door still no defrost

[sjc]

I have an 07 F150 XLT that has no defrost air flow. I read on here that the mode door could be jammed. I removed the actuator and sure enough the mode door was stuck. I was able to free up the mode door and reinstalled the actuator. The actuator is moving but still no air flow through the defrost vents. Does this seem like dash removal is necessary, or maybe something else is needed?

[blackonblackfx2]

well on mine it just got something blocking the blend door and i brought it to the dealer cause i didnt wanna remove my dash and they told me thats what has to be done..5-6 hours to re & re dash then whatever else it takes to fix it
..its ridiculous, dealers love to give it to you hard

on mine it seems like theres just foam in there cause when you switch from floor to vent to defrost you hear a crunching foamy sound and it only works on vent