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So problem in linkage or controller.

Alright, another possibility ruled out. I have another '95 Legacy so I pulled the climate control unit off that and plugged into this '99 and no luck. All the buttons light up, so it's getting power, but it does not move that mode door. I also don't hear any noises like clicking or or grinding or anything like that. If I am understanding this correctly, there is a linkage mechanism that moves the mode door, which is connected to the actuator correct? I'm guessing since I am not hearing any movement or grinding or clicking, the actuator itself may be bad. If the actuator was functioning it would at least attempt to move the linkage and make noise. idosubaru to answer your question from above, no it wasn't a Subaru. It was a video on a 2003 GMC Safari which has vacuum actuated mode doors. Here's the video link if you are curious: https://www.youtube.com/watch?v=wcZNtRsD4jI lmdew - if i really get stuck I've got a guy at my church that can help me out, but I think I can probably figure this one out a step at a time. I'm a novice, but I like to learn.

It's not hard to pop those out when replacing a ball joint or even strut. So if anything like that was done recently, that's likely the answer. I don't think I've seen one pop out on their own. I would recommend replacing both the front differential gear oil (as it likely has some metal shavings from the slipping splines, and the spider gears likely got hot from spinning with only one axle connected), and ATF (as the transfer clutches got abused) after driving it like that.

Thanks again Moosens! Would you happen to have any info on the earlier clips? A picture, source or part number?