Broken blend door

I have read all of your advice on heaters and no heat. I took it for granted that my luck would be good and bought an actuator today. When I went to install it, the female "D" shaped plug fell in. So now I know that something internally is broken. (not to mention that when I pulled the actuator out and tested it, it rotated with no problems) Can anyone help me and walk me through the "home repair" version of this so I can spare myself the $12-1400.00 repair right at Christmas time. Any help would be much appreciated!

My Windstar is a '99 and it doesn't have rear air or heat.

Not really sure what the problem is, could you describe the situation a little more?

Not really sure what the problem is, could you describe the situation a little more?

The actuator that moves the door that rotates from hot to cold inside the heat and a/c plenum has broken. I have read some threads that mention a way to cut into the plenum, remove the broken part or parts and repair them.
This door or "flap" is operated by an electric motor that rotates at about a 90 degree angle.
I know that there are other parts inside, and I don't want to have to repair any more damage so I'm aprehensive about where to cut.

I found a kit that repairs the broken blend door problem with no dash removal and takes about an hour. The kit is called the HeaterTreater and they have installation videos on youtube. check it out: www.heatertreater.net