While replacing my blend door actuator (specifically, while removing the hidden forward screw), I broke one of the two square tabs on top of the blend door shaft. I tried to turn the remaining one with my fingers but was unable, so perhaps it is jammed inside the box. Has anyone been through this before?

It appears that i will have to remove the heating coil to get access behind. I suspect that the blend door itself is a dealer part.

I am holding out hope that i can think of a sneaky way to repair or modify the tab at the actuator motor, to avoid disassembly of the box.

Ideas? Thanks.

 

Don't like being the bearer of bad news, but, the entire instrument panel must be removed from the vehicle before the heater case can be removed & split apart, to fix the door. Might as well replace the heater core while you're in there. If it needs a new door, you have 2 choices: Dealer or boneyard. Depending on the year of the vehicle, certain parts have been discontinued. If you haven't had the "pleasure" of doing this job, plan on a full day of work, and you'll need an assistant for some of it.