The blend door often sticks because the heater box as a whole has warped. I solved it by removing the "door"and examining it for small surface marks where it was dragging. I then slightly trimmed the door so it conformed with the warped shape of the box and then replaced it... problem solved. I removed a smigeon more material than was probably required because I figured the box might possibly warp a bit more. Good luck with the re-install.
MY99 RR P38 HSE 4.6 (Thor) gone (to Tasmania)
2020 Subaru Impreza S ('SWMBO's Express' )
2023 Ineos Grenadier Trialmaster (diesel)
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