Hi Eric, I have a 94 legacy with the same problem. I don't think that anything is stuck in there, but it's possible I guess. I have done a little web research and found that 92-94's have a problem with their "Heater core: A clicking noise caused by the heater mode door actuator can be fixed by installing a new resistor in the wiring harness. "
I don't know where the new resistor goes or where to find one. Maybe with two heads working on this problem we can figure something out.
I'll keep you posted with what I find,
Jason
