Oooh, envy! My '05 Type S has same issue, so did exactly the same as you, but to no avail. My blend door is extremely difficult to move. I've no idea what is jamming it up, but it absolutely will not move freely. Worked fine for years, then suddenly...View attachment 571238
I recently had issues with my actuator not moving fully in either direction. The fix for my issue was to remove the two moving gear/pieces, cleaning them up and adding more grease to the meshing parts. I was dreading it being the blend door itself, but once I removed the 2 parts, I could spin the gear for the blend door effortlessly.
I'm in SoCal High Desert where summertime temps are typically triple digit, and winters get below freezing. Removing the bloody dash to get to the blend box is just not worth the trouble (at least to date) as I typically run the AC all summer and heat only in winter.
When it's time to switch, I slide under the driver's side dash and with key on, turn the temp control to either full heat or cold, then manually twist the blend door gear to "help it along"... It does not move easily, but does move. PIMA, lol... One day I'll sort it all out properly.