Thanks! I did wonder if it was not a good idea so decided not to risk it. I've put in a manual adjuster mechanism (AKA coat hanger) for the rh blend door and am putting it all back together so I can use the car until I've sorted this out properly.
I've found a link to a guy in France that makes brass gears for the blend motor - but only the two larger ones. Doesn't help the small gear that appears to be partially stripped in my car. I am tempted to buy these and get a used motor and use the hopefully good small gear out of that. The motor assy is pretty new by the looks, although I should check the pot works before I think about just replacing stripped gears.
This blend motor is used in a variety of other makes and models - Peugeot 405 and early (I think) 406, for example. There was some chat online that the Peugeot ones use brass gears but from what I've seen online of their motors pulled apart this is incorrect.
Ultimately this is a dash-out job. I want to fix the blend doors properly, and also thinking about replacing some of the parts butchered in there. Eg the inst cluster surround is broken on the lower attachment points. Even the upper attachment points have been broken in a previous repair attempt-- but I'll make up some aluminium brackets and glue them on when I have time. There's also a bit of creaking going on over bumps that I think are dash/console parts. I'm thinking of somehow buffering these so they don't rub together.
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