Blend Door is Leaking

Warmer weather in the afternoons, so time to start using the AC again. On full AC with outside temp of 70, I'm getting 60+ degrees out if the center vents.

I'm was thinking low on freon. Today I hooked up the gauges and checked the high and low pressures. Pretty much dead center of where they should be at the 70 degree ambient temperature according to the FSM.

FSM says if pressures are good, but air isn't cold, blend air door is sealing improperly.

I take the electric actuator off the blend air door and open it fully by hand. Temperatures go to 45 degrees. The actuator is going fully from mark to mark when I adjust the temperature knob.

The blend door isn't fully sealing off the heat when the temperature is on full cold.

Has anyone else experienced this issue & more importantly does anyone have a solution?

May have found a solution.
See picture attached.

The worm gear turns the white gears. The large white gear with the metal coupling also turns the blue gear. The blue gear is the feedback to the actuator. If it turns too far, the actuator reverses. (It is mounted on the shaft of a potentiometer or encoder.)



Yesterday, I only jumped teeth between the white gears. I needed to jump teeth between the blue gear and the big gear. I did that & moved it over about 5 degrees. The actuator is holding the blend door fully cold now.

My only concern is if I have gone too far and the actuator is constantly trying to reach a point it can't get too. Not sure how I could check for that. I'll have to ponder some more.

If that's the case, I may eventually burn up the actuator. I have a spare coming.

I'll have to check the heat side one morning later this week. I had plenty of heat, so I don't think it will be an issue. If it is, I can use the other actuator and swap them when I swap tops as the seasons change.

Used a stethoscope today to ensure actuator is getting to a stop position. Had to pull the relay on the blower to eliminate the nose from the fan. All good.