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Plastic mechanism on duct
I had the same prob, even worse. There is a plastic part on the duct flap/door mechanism. On the drivers side under the dash ofcourse, look at the duct system. You will see a flat plastic piece with the cable connected to it. It will also have a screw in the center. Remove the cable, cable clamp, and the screw holding the flap/door controller onto the duct. Look at the side of the flap controller nearest the duct you should see at nipple/stud protruding from the surface. There are actually a total of 3,and are visible unless they are broken off. Two of mine were!! Those studs are inserted into the flap actuator shafts (slots on the other plastic duct pieces) and they alll work together. I fixed mine with some shafts used for Photo Album Page refills (genious) by drilling a small hole exactly where the stud was and then "sandwiching" the plastic with 2 of the photo album shafts thus re-creating the broken studs. Then I reinstalled the whole mess, lubed it, and adjusted all the crap.
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Sometimes you have to take the Bull by the tail and face the situation..........WC Fields
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