Okay, here goes my crappy attempt at a DIY...
Remove the side panel and knee bolster. The side panel is a pull off (easy). The knee bolster is not difficult, just remove the two screw on the bottom and one bolt behind the parking brake pull (It holds the parking brake release. Once you remove the bolt just swing the cable and latch out of the way...
To get the knee bolster off just pull firmly and it will release the metal clips from the sockets.
Now remove the floor vent duct. There is one plastic push pin that you remove towards the driver side (circled in red). Once that's removed just pull it off.
You will be able to see the actuator held in place with two small bolt/screws and the small electrical connector. Simply disconnect the connector and remove the two bolt/screws and then pull straight back while managing to push with you other hand to hold the gears keeping them from pulling out as well. This is where it helps to have smaller hands. I still cut the hell out of my left hand...
One note... When you put back on the new unit, you'll have to move the gear so that it centers back into the actuator groove... you'll understand when you see it.
!!!This part is important!!!
When you connect the electrical harness and are all ready to go... before putting everything back together, turn the ignition on but don't start the truck. Power on the climate control unit and let it sit. If you stick your head under and watch, you'll see the actuator cycle through and re-sync... it needs to do this or you'll be going to the dealer. Shouldn't take more than 30 seconds.
Following this, you can cycle through the modes (Vent/Blend/Floor/Defrost-Floor/Defrost) and watch the actuator move the gears/door. If you did it correctly.... you'll see everything meshing and understand how the system operates.
---------- Post added at 09:45 PM ---------- Previous post was at 09:41 PM ----------
Here's the unit with the new one on the left:
And here is the old part disassembled. It appeared to be functioning but something was clearly not working with it.
If you're in or near Columbus and need this done... I'd be glad to help out as it's pretty easy.