Just a follow up (as I hate dead end search results), I found that you can access the floor/defrost blend door from under the driver side, just have to reach up and undo the 2 screws holding it in. Wasn't hard, and saved a bunch over the dealership doing it I'm sure.
First, I've got a 2007 Expedition without dual zone air.
I've had the clicking blend door for a couple days now and just got a chance to check on it. I pulled everything out and found the actuator referenced here, but I believe its to control the heat/cool blend, not the upper/middle/lower...
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