Well, I got it back together. It worked perfect for a minute or so then it went back to just coming out the vents.

carfixer: I could not move the rod with my finger.

The door must be hung up. You'll likely have to pull the dash to get the system out and repair whatever is binding the door. I was sure hoping you could fix this in car but it looks like that is not going to happen. The dash is a bit convoluted but you can do it if you want.

Well here is the thing, I just mostly buttoned it all up. Started the car, heard the actuators doing there thing & now I have defrost air & heater.

I was going to have you stress test the actuator as it may be the problem. Change the setting with no radio or blower and see if you can hear clicking. That would indicate the actuator has stripped gears.

So, I reread your last post and it sounds like it'* working correctly. Is that right?

Now I think the mode door is stuck on defrost & floor. I am going to play with it for a few days & see. I am not convinced all is well. Thanks.

Turn everything off and listen as you change the setting. Does it click?

Nope. No clicking. It is now back to coming out the vents only.

I am wondering if it can be the climate control head or the instrument cluster module? According to my info, both control input to the HVAC actuators. I did the re-calibration per the instruction in the earlier post & again, the air came out the proper position for a few seconds.

It doesn't make sense that the door would stick intermittently. Try smacking the dash in the area nearest the head and see if it starts working. There may be a bad connection in the head or at a connector.