[Sour Kraut]

Ford / Mazda Blend Door Fix

You might try a using a drill bit insted of a nail. However, I would be concerned that the blend door is binding and will eventually shatter.

You can buy a new blend door on ebay for about $19 delivered and install it using the instuctions and pictures in the Ford Enthusiasts Forum.
This forum has pictures and instructions of every blend door repair conceivable.
These run the gammet from removing the heater box by removing the entire dashboard including the steering column (Only for the very brave or foolish. Warning these pictures are very explicit and may cause emotional distress.)
http://www.explorerforum.com/forums/...ad.php?t=59787

To the pin in the actuaor trick that you have tried.
I have a hunch that the best way to go may be to replace the blend door completly by cutting a hole in the bottom of the heater box.

Some pictures of what you might face with this fix are shown on:

http://www.ford-trucks.com/user_gall...&albumid=12494

If you search both the above forums you will find a ton of info on the blen door problem