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Jstic - thanks for all the info you have supplied. I, too, have this problem and I'm debating what to do next. I have disconnected the actuator and crunching noises have stopped. I'm also thinking that since I have done that the air flap is now in its recirc position - correct? If so, that's fine with me. During the summer months down here in FL you need the AC to be in the recirc position while during the winter months the AC is off and the windows and/or the top is down. Am I doing more harm than good by keeping the actuator disconnected?
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