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Blend door Acuator fix NC, mine is a 97 and the pin is plastic. I did drill off center, because that is the only way to get the nail in- the pin doesn't actually drop into a square, it rides along and nests into an "L" or "V", so you need to offset the nail. Hope that helps.

Blend door Acuator fix Awesome info and got me well on the way to the fix- thank you Robb for the link. I would place on amendment to the location of the holes you drill in the plastic stud: I found that I had to drill the holes on two adjacent sides (square) of the stud to make the door move...