Maybe something fell in there? If you look from the rhs under the dash you can just see the cable mechanisms, might give you some clues. One of the plastic clips that holds the cables in place behind the controls on my 95 D1 broke and I wasn't able to select demist/face/floor properly. I got a cable tie in the right spot and fixed it. The round heater/demister controls should not be difficult to move when they are working properly, if they are stiff or stubborn maybe check the cables, that could be your rattle too?
Sent from my B1-730 using AULRO mobile app
Paul
1971 IIA ute, 186 (Betsy)
they're not dents, they're character...
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