Checked vac. lines to the diaphram are good, the one door that is
connected to the auto temp control sensor makes a clicking noise louder when the air is being used could this be a bad sensor
Well you are going in the right direction remove the four screws from the mode door actuator and move the door manually and see if it move freely if so move the selector switch on the dash and with the motor unbolted see if it moves properly don't forget you may need to apply a little resistance with your finger to find a problem with the actuator. good luck but both the mode door them selves and the mode door motors are vary common problem.good luck
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