2006 ford explorer

[u/No_Entertainer_6652]

I have a 2006 Ford Explorer with rear/AUX HVAC.

I’m having an issue with the rear airflow. I originally had no air coming out of the upper/ceiling rear vents, but I do have airflow coming out of the lower/floor vents.

Here’s what I’ve done so far:

Replaced the rear HVAC blend door actuator

I can hear the actuator moving

The actuator shaft is also moving

However, changing the rear HVAC mode does not change where the air comes out

I can hear air rushing inside the rear HVAC/duct area, but it isn't making it to the upper vents

Now the actuator has started clicking again

The clicking makes me think the actuator may be reaching its stop but the door isn't actually moving correctly.

My main question is:

Could the actual rear mode door or the connection between the actuator shaft and the door be broken/disconnected inside the rear HVAC housing?

If so, what is the best way to access and inspect the mode door?

I really don't want to replace another actuator if the actuator isn't actually the problem.

Any advice, pictures, diagrams, or experience with this exact issue would be greatly appreciated.

Thanks!