I need some help with some issues with the blend door on my mom's 2012 Fusion. She has had it to a couple of mechanics and they have been unable to find the issue as its intermittent. The AC will run ice cold for a spell (1 to 5 minutes) then kick over to full heat. When this happens the blend door actuator is turning the blend door over to full hot (I had my finger on it when it happened). It doesn't appear that the door is slamming closed like the gears are stripped. It slowly moved as if operated by the actuator. Once this happens it will blow full hot until you restart the car. Here is what I have tried so far:

• Replaced blend door actuator.
• Calibrate the blend door actuator with a battery disconnect (several minutes).
• Calibrate the blend door actuator by removing fuse 15 for 30 seconds, turning on the ignition for 30 seconds then replacing the fuse and turning on the ignition for 30 seconds.
• Disconnecting the blend door actuator and manually turning the blend door to cold. Blew cold for at least 15 minutes. I needed to cool off its about 90 out.

At this point I am convinced that its a blend door problem (see 4th bullet above) and the compressor and radiator fan never kick off. It appears that turning off recirculate/max AC, changing the cabin pressure by rolling the windows up/down and changing the temperature setting all trigger this behavior. The blend door is not easy to turn manually when the blower is on full blast, with the blower off its fairly easily turned by hand (no tools).

Anyone have any thoughts on next steps?