I too had this door shaft drake on my 90. And yes you have to drop the dash 
and then some more work to replace this part. I got the new part from the 
Dealer. The dash in the 90s pivots down and then you must just about remove 
the air-box the get the new door in, (NOT FUN).  the FSM shows all the 
steps to be done. Not any thing hard just a lot to do.
You can remove the radio and the ATC controller and the lower half of the 
dash them a few peaces of duct work and you can just see the point that 
the actuator rod was to attach to the rod out the top of the air box that 
would have moved the door.  If I remember the door is called the MODE 
DOOR.
This is the only way to repair this door if broken. But if you are lucky 
the actuator rod may have just popped off, you can see this if you remove 
the radio and so on.
Now if the actuator rod looks like it is OK on the pin to the MODE Door.
One other thing that I have seen go wrong is that this MODE DOOR has two 
parts to it, this lets the system to BI-LEV. I have see this two part door 
fail the the front half move freely and not let air to dash. The fix is 
the same, replace the door.
--
Alan Jordan
90 IMP
75 LeBaron
75 LeBaron Crown Coupe
-------------- Original message ----------------------
From: "M. Esposito" <cadmat@xxxxxxxxx>
My 90 does the same thing, I never took the dash apart, but I have heard 
quite a
few folks dealing with the same thing, I think it is a design flaw, the 
tab
between the actuator ( motor) and the actual blend door lever, breaks. So 
you
wind up getting air out the defroster vents or the floor...from what I
understand it is a mechanical issue, not vacuum one. Occasionally, right 
at
start up, if your A/C is already on, you will get air from the vents for 
just a
moment.. but apparently the dash has to come apart to access the broken 
lever
piece... again, I havn't actually taken the car apart yet, so i can't 
speak from
experience... anyone else wanna' chime in who's actually fixed it?
J-C <jchudd@xxxxxxxxxxx> wrote:       I have a 90 that now onlys blows 
air out
the  defroster or at the floor. Is this a blend door problem? Maybe a 
vacuum
issue.  Anyone have any advice on the fix for this? Does the dash have to 
come
apart for  servicing those actuators and doors?  Thanks Jeff
 90-black
 91-blue
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