2011 Lincoln MKZ - A/C Troubles (again!)

a99tandem

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Hey Folks, heres the short form version - 2011 MKZ Sport pkg - 83k mi.

I took my car in for the a/c chirp under my Premium Care warranty - they had my car 3 weeks, and instead of replacing the blower motor, they ripped my dash out and replaced the plenum and a bunch of other parts that were supposedly busted. But, upon getting my car back the dang chirp was still there, and even worse my dual zone air stopped working, so the passenger side only blows ambient air. Take it to a different dealer, because the first one was kind of fishy and seemed like they were doing some kind of warranty fraud. I called Lincoln about the issue before selecting a different dealer. The new place then has my car for over a whole month- 34 days. Again they ripped out the dash, waited forever to get parts, replaced the plenum and blend door actuator. I get it back and everything is great.. until its not. Chirping returns 2 weeks later, and now dual zone air is busted on passenger side again. Its getting a bit ridiculous. Tried resetting the HVAC system by pulling the fuse, tried resetting BCM by disconnecting the battery and using a jumper wire to clear the KAM. Nothing works. Still under warranty for another few months, but wanted to get advice- I see ton's of a/c issues on this forum. I know the blower motor is an easy fix- and frankly wish I would've bypassed the whole warranty process to begin with an just fixed the chirp on my own. I'm getting it repaired again under warranty- but after February, if it happens again it'll be out of pocket. I've done quite a bit of Googling, but can't quite tell- is the passenger side blend door actuator easily accessible?
 
The passenger side blend door actuator is behind the glovebox to the left of the cabin air filter housing. It's easily visible with the glovebox removed, a bit of a pain to remove, but can be done. However, I find it hard to believe that two brand new plenum assemblies and blend door actuators have failed. I'd start to suspect the control module, but that's just me.

There was an issue with some older Explorers where the control module would fail to stop the actuator motor causing the blend door actuator to actually break the shaft for the blend door. At least on those you could replace the blend door separately - I'm not sure about that on the MKZ, but it would still entail removing the dash and plenum.
 
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