|Release Light and Harness|
|Remove the CD Changer|
Once the air duct is out you have access to the actuator.
The passenger side mix door actuator can be seen here to the left of the heater tubes.
|Passenger side mix door actuator can be seen by looking to the left of the heater tubes and|
locating the yellow bushing partially obscured by the large white air duct.
The actuator is held in place with three screws. I had to pull the heater tubes slightly to the side to access one of the screws.
Once the actuator was out I decided to try and repair it before buying a new one. I opened the case by gently prying open the side latches (be careful, I broke a couple of tabs) and cleaned the resistive position sensing traces on the back side of the main gear. I soaked q-tips in alcohol then held them against the underside of the large gear while spinning it around. After several q-tips the residue eventually stopped coming off. Now that the sensing traces were clean I used another q-tip to pick up a little dab of excess grease and smeared it on the underside of the newly cleaned gear.
Finally, I put the actuator back together and made sure it worked as expected (it did) before re-installing the rest of the parts.
---> Fixed in about 2 hours for free.