When I first read your OP, that was my first thought, blend door actuator, mine started messing up about five years ago, but has never gotten much worst, maybe mine is not as bad as yours, mine only seems to hang up on heat sometimes, I know that when I feel the heat on my feet on a normal day, it will straighten up for me if I move the a.c.c. selector to another position or two, other than that mine is working fine......Thank God that actuator is available by several vendors, I'm not sure which one Ford used as an o.e.m., I have not been able to figure that out yet, I'd like to go with what Ford used o.e.m., whichever it is, there's about 6 different brands the last time I checked, been a year or two.....I've been looking into this swap out over time and from what I can figure, it's remove glove box door and we have to cut one of the four hold down loops to get out and when we go back in we have to remove that loop on the new actuator and this time it will be held in with only three screws, which should be fine, now I've removed my glove box door and moved my seat back all the way and hung my head under there a couple times and if you look for the plug-in you'll see where exactly it is (driver's side, top) and from what I see, it looks do-able, I have just not got around to it because I've been doing other projects on my Bird..........But, by gosh, hang your head under there and tell me what you think, the glove box door out of the way provides big time access to that area and provides a little light and only takes 2 seconds to get that door off..........
