A couple weeks ago I tried to replace the RH blend door actuator only to find out I had been sent the incorrect part (after I removed the original part). Today I finally received the correct part, so this evening I set out to install it. It didn't go so smoothly this time.
Getting the old one out was np until I got to the plug. The plug, which came out easily last time, was stuck this time. Once I finally got it out, I figured the rest would be clear sailing. I laid the new part in and ... f**k, it doesn't line up. Now I've got to plug everything back in just to get the piece that connects to the actuator to reset into the proper position. As I pull my arm out of the dash though, I bump the flashlight that was sitting on top of the factory amp and it goes plummeting down into the abyss (inside the dash). Luckily, it was still on so and fell in such a way that the end was pretty easy to reach from the lower part of the center panel.
Now I get back to reconnecting everything and after running it in ACC for a moment and hearing the piece moving, I shut it off and start pulling everything back out. I try again with the new part and now it lines up. Whew! I carefully thread the screws back in, using 2 hands for the one in the back as I really don't want to drop the damn thing into the abyss. I get them both in, tightening the front one with a socket wrench and the rear w/ an open end wrench. Neither my hand nor my arm really fit back there though and I'm having a really hard time getting that screw snugged all the way down. My hands starting to cramp up too, so I'm worried about dropping the wrench. I decide it would be easier and safer to try and finish up with the socket wrench. I get a couple turns in and then ... the tiny socket wrench slips out of my hand and falls into the dash. Fuuuuuuuddddgggge!!
I spent the next 20 minutes trying to find the damn thing using my flashlight and an inspection mirror. I finally spot it at the very bottom of the dash in an area that I can't possibly reach. Wait! I notice some plastic clips in the driver footwell towards the back of the center stack. I yank those and am able to get the side panel pulled out just enough to stick my hand in there and (barely) pull the wrench out with my fingertips. Now I finally get back to finishing the actual job and thankfully, it goes smoothly from there. I run the HVAC and everything functions as it should with no more clicking. Next time I work through the dash like that I think I'm going to run some fishing line or something around my tools. :x