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Yeah, a case in point was a guy who innovated a welded steel part to fix a plastic coolant passage in the intake manifolds of 2000-2002 Saturn S-Series cars...his parts are top knotch, made in a small shop in Georgia. Cost $80 and worth every cent -- He will email me back immediately if I need...

Yeah and niche stuff like this is fairly low volume, so the full cost of the tooling gets spread over a small run, leading to $20 small parts. Still better than $40 for a whole actuator if only the gear is broken I suppose.

Domestic production of parts like this is getting more and more rare, it seems. I hope there will be a resurgence of American manufacturing in the coming years!

Rebuild kit available! Looks like you can get the gear only and save $$$ now! http://www.amazon.com/Actuator-Rebuild-Lincoln-Mercury-1990-2012/dp/B01FIIWM90/ or eBay http://www.ebay.com/itm/182120579591 Hope that helps someone as the weather gets hotter and we all need A/C more than...

If your actuators are anything like mine, they like to crap out a lot, and it's usually just that one little gear. Just so you all know, the gear that breaks in the heater blend door actuators is now available -- Saved me serious $$$ over buying the whole assembly again...

Is it AWD? If so, a bad viscous coupling in the transfer case can cause a popping while accelerating.

I have an offer on the table in another thread to rebuild actuators for up to three people free of charge for beta testing of new parts. First come, first serve, PM if interested!

Folks, I'd like to try my hand at to rebuilding a couple of these broken actuators free of charge. My buddy's broke and the gears are so far gone I need something to look at to figure out how to fix it -- so hence the offer! I'll do it for up to 3 people. If you have a broken one...