Yes it's a common problem, with it and it's brother the Edge and still is with the newer ones as well, the thing is that there are also multiple solutions depending on the failure. On the few I have done they have had a couple of bad actuators, two that were the plastic doors themselves. They had broken and the shaft just moved the broken part around. If it had been a vehicle I owned I would have tried a few "unauthorized by Ford" repairs to make the various parts more durable. Only one was repaired by doing the HVAC reset, and it only lasted about 2 weeks and failed again. I've also talked to folks who have unplugged and then reconnected the actuators and had things suddenly work again.
I do know of one person who got rather upset at Fords design and their response to the issue who removed the actuator and added a push pull cable for the drivers side blend door!
One thing you might try, get one of the cheap inspection cameras that connect to your phone and slide it into the case and watch the actual door movements while you actuate the system. That would tell you a lot.
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Tuesday, January 7th, 2020 AT 2:26 PM