So I finished this job and got the new actuator in, pulling the right side of the dashboard forward to get access to the bolts. The blend door itself moved freely and I installed the new actuator with two bolts. Its in there solid and not going anywhere. Previously, it blew hot air regardless of the temperature control setting. Now the manual temperature control works properly. Glad I got this done. Temperatures here in Upstate SC are forecasted to be in the 80s by Thursday. That will be a good chance to see how well the AC works. A short test today says it will work just fine.
Doing this job sucked but it sucked less than kicking out $800 to the dealer, so that puts me on the plus side I guess. If I ever have to do this again, 7mm and 8 mm offset ratcheting box end wrenches are a must have. Except for the BDA itself, looks like Ford used some common sense by using common tools and fasteners when putting the instrument panel trim panels in place.