After taking out the passenger'* side A/C actuator (behind the glove box) because it wouldn't turn at all when switching between requesting 60 & 90 degrees, what is needed to make the new one go in it'* place? The brand new one is positioned such that it'* beyond the angle that it will fit, and when plugging the electrical wires into the new one it doesn't seem to want to turn either, making me wonder if this was the problem to start with.

Does one need to recharge with refrigerant first before expecting both of these actuators to turn? The actuator for the driver'* side (never touched) seems to turn just fine, except that all the cold air now seems to come out of the passenger'* side (A/C door manually turned that way) and only cool air (not cold) comes out of the driver'* side. Thanks to the recent mention of low refrigerant first being noticed on the driver'* side (sounds odd, but I'll go with that). Right now I'd just like to get this actuator in place and figure out why the passenger'* side just doesn't want to turn.

Thanks in advance.

If you can reach it, try turning the the door by hand to get things to line up. Otherwise, add some freon first to see if the actuator starts to work. Being low on freon has caused the cold passenger, warm driver'* side issue.

Thanks Archon. The position of the new actuator is past any angle of turning the door by hand (neglected to mentioned I'd already tried). Wish they'd supply it so it'* an easy install and positioned somewhere in the middle. I guess I'll try adding refrigerant and see what flies.

I should have said refrigerant or R134 instead of Freon. Thanks for being kind. While it was low on R134, adding some helped out a bit (yet still not cooling properly and think it'* now on the high side of allowable low/high side pressure for temp/humidity...need to verify later). The one actuator behind the passenger'* glove box (read there'* 4 actuators) still doesn't want to turn. Seems a shame this humongous 2-volume maintenance manual doesn't explain some simple process/maintenance things and goes into great detail on some things I'd never consider doing.

Freon is the generic term for all classes of refrigerants, so using that term is fine in general use. r134a tells which specific refrigerant.

Can you get the actuator part way on at an angle that will line up with the door and then twist both to the proper position?

Nope. Tried and tried multiple times. And yes, I can be quite determined. When it comes to electrical things (it just had to be a motor), I'm typically "All Thumbs". I'll try monkeying with this a bit more (like disconnecting from the battery for a while to see if anything wants to reset by some miracle). Getting the old actuator out was a breeze. Now putting the old or new actuator in is going to be a challenge, because the single time the actuator turned was after plugging the old one back in and now it too has turned beyond the point of reinstallation. I think its turning may have had something to do sometime after disconnecting the battery (which I don't believe happens consistently).

At this point, I like my wife'* typical saying: "It must be something electrical".

Using the description here regarding the operation...
AIR DELIVERY DESCRIPTION AND OPERATION
as well as the terminal layout here...
Diagrams
you may be able to apply voltage to the actuator to turn it to the position that you need. However, start with removing the battery power, then have someone reconnect the battery while you watch the actuator. (I believe it goes through a reset when it loses power.) Have that person then remove the connection to the battery when the actuator is in the position that you need.

Thanks again for info Archon. Would you by any chance know what actuator it is that'* directly behind the glovebox (air temp left, air temp right, mode, or recirc)? When I move the door from one direction to the other, it seems to direct more flow to either the driver'* or passenger'* side. So I'm guessing it'* one of the first 2.

There are two actuators under the driver'* side and one on the passenger'* side.
The one on the passenger side and one of the ones on the driver'* side determine the temperature on those specific sides of the vehicle. The other actuator on the driver'* side determines the "mode"setting.

So, to answer your question, the actuator under the glove box determines the passenger side temperature.

That'* correct. The passenger side actuator controls the temperature for the passenger side. Probably a bit late now, but this is the replacement procedure.
Air Temperature Actuator Replacement - Right