I have one small safety potential problem. The link that connects the fresh air/recir broke. So in colder weather if you do not have the AC on all the interior windows will fog up quickly. Not a good deal especially if you have the wife and grandkids as well.

So in review:
I can see that actuator is working in both directions. The air intake door moves easily, but stays with the door closed to the outside air. You can move the door to allow for outside air, but if you go to “Max AC” setting or hit the recir button, again it sets the fresh air door closed.

The issue is the repair to replace that damn broken link may require a complete dash & HVAC removal(?). I can barely see the broken link but it’s not an easy access as the link is almost hidden by the dash frame, vent tube, HVAC housing and a big wire harness. Ouch!!! I will need to remove the actuator to get to the broken link. But this repair is not accessible.

So my question is: Has anyone found an easy means to access these parts without a massive tear down?? All I see on YouTube pertains to the other blend doors. Which these other blend doors are much more accessible.

Thank you on your ideas and thoughts

Red area is the location of broken link. Yellow is the temporary fix to “return“ the door back to fresh air mode. Not best solution, but better than nothing.

 

I didn't have to repair a broken link, but I did have to replace a blend door actuator as it gave out and was stuck solely in a heated position. Looking at your profile and the familiarity of that picture, you have have the same model as me but just a different picture. I was able to get back there and replace it without having to do anymore besides removing the radio and airbag...albeit was not a fun time. Took me 3 different attempts and probably a total of 8 hours to successfully replace it. There's just not enough room back there to get a wrench (even if you have one smaller than your hand) back there. Somehow I did end up getting a wrench (after dropping on that is still lost somewhere inside my dash to this day) on the screws that hold the actuator in place, but could only go like 1/16th of a turn every time. Additionally, I don't have large hands, but I definitely don't have small, skinny hands. Had my hands been any larger, it would have been impossible for me to get back there and do it.

If this was wintertime, I would suggest just using living with your temporary repair and searching for an easy fix solutions when your bored. But since its summertime and not a miserable time to work outside, I would take the time to properly fix it and find a way to get to it while removing the minimum amount of things in your dash. If you get it properly fixed before the weather turns bad, great! If not, at least you know how to arrange the temporarily fix that will work until it doesn't.

 

Thank you on your thoughts! Yes maybe the Temporary repair may become my permanent fix.
But like you indicated maybe another idea might present itself.