Blend door

[Omegaman]

I worked on getting the actuator out and it was fairly simple with only 4bolts. I took it apart and it looked fine all the teeth were good so I think it must be the door itself. I just didn't think the door would be making that popping noise as I thought it was a fairly simple design that the actuator was just turning the door but I will examine the design further unless anyone could explain why or how the door would make that sound.. The door moved when I flipped it with my finger ....could maybe been bound up and got stuck?

Thanks , Omega
Ok took the actuator apart again and did find teeth missing.next to the little worm screw.