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Didn't read the whole thread but may have useful info. Bought an 04 with good heat but wouldn't switch to cold with the dial. I could manually switch it on the firewall in the engine compartment where the blend door cable attached.

Found a bunch of crud on the blend door gear under the dash. Also found arm completely broken off of blend door actuator motor mounted above blend door gear under dash. Found an used motor on eBay for $20. Problem solved.
 
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