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It may be that one of the actuators has come loose and isn't swinging the blend door completely. Might do a search here for it, it seems a couple years ago a number of us had similar problems with actuator mounting screws coming loose.
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ASE Certified Master Automotive Technician w/L1.
ASE Certified Master Medium/Heavy Truck Technician.
Certified EVT (Emergency Vehicle Technician)
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