So I did mine yesterday and it was a LONG day!! Everything went as I kind of expected. The bottom mode door does have the shaft that can slide in farther than the motor can reach. It seems pretty tight though so I left it as is. (Probably should have put a spacer or cut the mounts down) I checked operation with everything and it all seemed to be correct. After putting it all together and actually running the truck I still don't have full airflow to the vents! It's better for sure but not what it was factory. Not sure what the problem is.
Also as a side not i want to make a **** lie you did for the rear vents. Those seem to have a lot of air flow!

 

That's great that it went well! I wonder if there's anything else blocking the flow, or if it's worth testing it without the screen? Or maybe - did you replace all of the foam on the top of the HVAC box and the duct that goes to the firewall for fresh-air? Mine was in HORRIBLE shape, so I'm pretty sure the fresh expanding foam helps prevent some leakage of good air behind the dash and/or mitigates hot, fresh air coming in when in recirc mode.

FWIW, as it's heated up here for the summer in Arizona, the **** works really well, but the extra air flow doesn't necessarily make a world of difference. I'm still glad I did it and retained full functionality (and then some), but don't feel like you're missing out on ice-cold front seats

 

I did not replace the foam but I probably should have! It seems like the upper door is not going down all the way to force the air up to the vents. I did notice that when I put it to fresh air A/C it seemed to blow harder from the vents. Not full force but better. Just not as cold because it's the fresh air setting. I'll be pulling the dash back again now that I know it is actually easier that I first thought. (I pulled everything apart when it could have all been left in place!! ) I'll check function again and replace the foam. What foam did you use? I'll also put spacer to make sure the bottom shaft doesn't slide in and off the actuator!
When I select max A/C with vent and floor I get good flow to the floor. When I select just vent the floor goes almost completely away but the vents stay the same. I also noticed I get some airflow to the defrost. Not sure if I should have this or Zero airflow to defrost.

 

I used this stuff, but cut it lengthwise so it was only 1/2” wide (about right), but a nice and tall 1”. Had to compress it pretty well and then work fast to put the recirc plenum back on. The top where the mesh screen is wasn’t as bad, thankfully… because I doubt I could’ve placed the whole dash appropriately quickly enough.

https://www.lowes.com/pd/M-D-13-ft-E...rstrip/3434324

I don’t think I have any noticeable flow from the defrost, maybe something with the mode 2 door not sealing perfectly?

 

Cool Thanks!
Yeah I'm going to have to remove the dash again. Not too bad now. I'll have to just double check everything and add the better foam gaskets to the top. Thanks for your reply!

 

Hey. In case anyone stumbles unto this old thread from a google search, I figured out a down and dirty way to get rid of that nylon screen blocking airflow to the front vents without having to take the dash apart. I made a YouTube video showing the steps. Good luck.