Dunno if it will help long run, but after reading all the Blend-Door problems, I leave mine on the next to the last position (defrost w/ a bit of foot heat) all winter and then move it to the A/C - Fresh Air position for the summer.
My hillbilly logic is (1) Only move the door 2 times per year and (2) Only move the door when the temperature is warm (either ambient or w/ heater on).
As far as I can tell, the door movement mechanism does not operate when the key is turned off and on; i. e. , it only moves when the knob is rotated to a new position.
I know this doesn't help if it's already broken, but according to this forum, the replacement door is the same POS.
FWIW,
Jim DeMont
Medford, OR
2004. 5 White Dually Six Speed