Since we bought this thing the air hasn't been really cold on the passenger side. I've done the hvac door relearn procedure before and it would get better for a while. We hadn't driven it in 2 months but yesterday we drove it to Sandhills and it was warm on passenger side, and one of the vent flaps wouldn't move to shut off the warm air. When we got home I did the relearn again and it stuck itself on full melt your face off heat. So, couldn't put off blend door actuator any longer.
Of course the passenger temp control is the hardest one to get to, on top of the heater box under the dash. I've watched a bunch of YouTube videos before, and last night, and decided to do the through the air bag hole method. I've read all the horror stories and 4-6 hours, etc. It took me 2 hours to get the old one out (including making the custom tool) and 30 minutes to put it back together after a run to the parts store. The actuator was $31 and in stock at Oriellys.
I won't recap the YouTube videos, but a couple observations. This being a quadrasteer, rear entertainment, fully loaded model, there was a harness attached to the crash bar that I didn't see in any of the videos. It's in the way but you can pull the Christmas tree retainer and move it out of the way enough. Also, I removed the dash panel where the quadrasteer button is. I didn't see that in the videos, but it gives you another access point and lets you actually see the left screw instead of doing it blind.
The screws are 7/32 and the midget wrench below worked perfectly for the right side screw. The left one is down behind the actuator where a flat wrench can't get on it, but a 7/32 socket and ratched doesn't have the overhead clearance to get in there. Enter the welder.
I took an old 1/4" drive "breaker bar" from a tool set my Granddad bought me from a yard sale when I was probably 6-8. Also took a 7/32 12 point socket from another tool set I have from my other Granddad. (It's important to use a 12 point because its very hard to get the range to turn it). I welded the socket on and tried it, but the handle was too short. I roughly measured how long the handle needed to be, and 6.5" is the ideal length. Long enough to reach across the actuator but not too long that it hits other things trying to turn. A piece of 1/4" square tacked on worked great.
Now the wife will be comfy on the camping trip next weekend.
Back to that vent that wouldn't close.... What happens when your wife tries to free it up and breaks it? You go out back to your Denali parts truck and grab some more.