Just an update in case anyone else has this problem. My blend door has been in the half-open position in the photos (as far as I know) since last fall. So far I haven't noticed any adverse effects. I don't know whether it's the worth the money and effort for me right now to try and fix it.
I really need to do this ASAP, my 2004 is way overdue for the timing belt and I just started hearing a squealing sound which I'm assuming is one of the bearings going out. Does this list include everything that can/should be replaced during a timing belt change? I'm trying to get an idea of how...
I was able to get a few pictures of the problem. I'm hoping that only the door is damaged.
Looking up, this is as far as the door will close.
Close ups of the spindle that drives the door. You can tell the the right side is damaged.
The motor does still work. If the door is in the closed...
So I'd been experiencing a clicking/shuffling noise periodically while the A/C was running. The noise was coming from the glovebox area of the dash and after some research, I came across a post about leaves in cabin air filter or even rattling inside the blower fan. I ordered a got a new filter...