An indy that I know does these repairs frequently - and when he was working for a Saab dealer's service dept., he was the "go-to guy" for blend door problems. He says that the plastic arm eventually just breaks when the plastic material fails.
(Under-designed part + plastic + age + heat + lots of mechanical stress = broken arm.) GM probably saved a couple of pennies per vehicle spec'ing a plastic arm when a metal one would probably last the life of the car. Besides, the "official" factory repair policy on these for years was to replace the whole box = $$$.
posted by 184.8.216...
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