I know the problem, and the fix, but wanted to see if anyone here has an idea why it's happening so often, and if there is a better fix than what I've been doing.
When you change the air direction to the main vents (2nd position on the slider) an actuator moves a plastic link that moves the deflector door. That link keeps snapping where it connects to the deflector door. I've replaced it 3 or 4 times, and have to do it again.
I have no idea what happens to the little piece that breaks off, but I'm betting those pieces will start causing me problems some day as well, but removing the box is one major bugger that would keep my baby out of service for a long time (and possibly beyond my skills).
I pulled the broken shaft out with a self tapping screw and the tiny bit that broke off, the retaining tab, is either still in the box or has been blown out of one of the vents. As it's small and plastic I suspect it's been blown out.
My 97 takes in leaves due to the cowl being more open than other years.Dig around inside the box,see if its packed with leaves or other debris that will jam the doors and break the levers.as for the deck screw extraction method, crawl up under there and screw directly into whats left of the broken lever.when you have a good couple of threads in,you should be able to pull the broken piece out(with some force) good luck!
Got it done. Just used a screwdriver to break it, then a paperclip to push the other end through. PIA task when you can't see what you're doing, and have to do everything by feel. Haven't done that since Tracy in high school.