Tore into it today. It was cold all day - got into it late in the afternoon.
My noise is coming from the right heater door actuator. There are two - one on each side of the driveshaft hump.
I almost got it off. The "pipe" that brings heater air to the right floorboard is in the way of the third and final screw holding the actuator. I think I can flip that gear over and just fix it like I saw in a post on here... I hope.
Anyway - how can I get that damn pipe off? I tried pulling the computer so I could see behind it but the torx bolts are in a weird angle and I can't get into them...