Can you update this on the outcome? My blend door actuator is getting louder and louder - have a feeling I'm on borrowed time. Looking back at my service history Toyota did replace the blower motor at the next service due to the slight bearing noise it was making. This was a separate issue.
The servo is actually a step motor that position the blend door where air through the heater core is mixed with ambient air to achieve desired outlet temperature. I suppose the mode actuator could have failed where only ambient air is discharged. You should be able to watch the mode actuator move.
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