Here is the Service Procedure:
1. remove passenger side insulator panel
2. remove knee bolster under steering column
3. remove the instrument panel module(remove screw, rotate up remove, disconnect harness)
4. remove driver air mix actuator
5. remove mode valve actuator

Not sure if you can get to the screws with the previous tool mentioned....may need a long quarter inch extension, universal, and 5.5mm socket

Hope this helps....I know there is not much room under there.....







Here is the serbv

What is the instrument panel module?

Nevermind. I think I found it. Is this it? I think that is whats in my way.

I got the actuator out. The panel module was what was blocking it. So I hooked up a 9V battery to terminal 5 & grounded the negative across 6 & 7 and I get movement.I tried moving the mode door with my fingers but they would not move. Was not sure if I needed to use pliers or how hard it should be to move. The other thing I noticed is the actuator is aftermarket not OEM. It has a plastic collar instead of the metal one the other actuator had. Not sure where to go now.

Here are pictures of the actuator.

That is not good that you can't manually move the door.....it should move easily....I hope you are trying this with the blower motor off.......if you can't move it manually, than that door is stuck somehow(something might be jammed against the door......have seen this happen in Cavaliers where the sponge-like sealer comes off and jams the door)........if you can't get it to move, without breaking it(the extension that comes out into the actuator), then the whole dash has to come apart to pull that hvac unit out, to take it apart and see what is jamming the door.....

That is what I am thinking. I went back outside, hooked up the actuators & they seem to be moving when I command with the air flow door. The actuators seem to go from one side to the other. They do not stop at different positions. Just back & forth. I am feeling a little over my head on this. Thanks for your help.

You are doing good. Don't give up now. The door should move with ease. I have seen some makes where the plastic tunnel will warp and not allow the doors to move freely. I don't remember that happening on GM models. The foam has been a problem with some.

What I tried is use the actuator as some leverage & the shaft turned freely. I am going to center the shaft in the actuator using the 9V battery & put it back together & see.

Can you rotate the door by turning the rod with your fingers? If so, than the actuator should be able to turn it if it'* not stripped.