[sheila]

You can follow this instructions:
Instructions:

1. Disconnect the negative battery cable.
2. Remove the glove box.
3. Locate the recirculation blend door assembly on the right side of the dash. It is located behind the HVAC control panel.
4. Disconnect the electrical connector from the actuator.
5. Use the 7mm socket and ratchet to remove the two screws that secure the actuator to the housing.
6. Use the flathead screwdriver to pry the actuator out of the housing.
7. Inspect the screw hole in the housing for damage. If the hole is stripped, you may need to replace the housing.
8. If the housing is in good condition, install the replacement actuator in the housing and secure it with the two screws.
9. Connect the electrical connector to the actuator.
10. Reinstall the glove box.
11. Connect the negative battery cable.

5.5mm/7/32" socket.

 

[sheila]

Rick, same thing happened to me with the drivers side temp actuator. 1 of the 2 mounting screw holes stripped. As GrizChev suggested, I just went with a slightly oversized screw. I just have to remember the screw head is now 8mm/5/16" instead of 5.5mm/7/32", lol. On another car, while replacing the drivers temp actuator, I simply dropped 1 of the mounting screws somewhere in the dash/console never to be found again. After spending too much time trying to locate the missing screw, that hole got an oversized screw also.

 

[sheila]

@sheila,

When you went with a slightly larger diameter screw, was it this same actuator location, and did you compare the replacement to an existing screw (wondering if replacement was longer)?

Worry is about blind thread holes where a longer fastener could do significant damage or interfere with surrounding objects. In cases like this I often grind the tip down since the female thread already exists (no need for self-tapping). Just wondering.

Iirc, the replacement screws were probably a bit bigger and longer. Both times were on the dreaded drivers side temp actuator, a stripped hole on one and a dropped screw on the other. I was so frustrated I just went to my junk screw inventory and eyeballed/grabbed something somewhat similar. I briefly considered blue loctite or silicone for the stripped hole and a trip to the local pick-n-pull jy for the dropped screw but those 2 ideas were quickly dismissed as I just wanted the pain and suffering to end, lol. The make-shift repairs were made 2-3 years ago and all is still fine to date.