2nd Gen Non-Engine/Transmission heater bypass "door"

[Rockcrusher]

The heater bypass door in my 2002 has stuck in the closed position since it was new. After driving about 30 minutes it will finally pop loose and open normally. Is there any fix without having to tear out the whole dash etc. ? I had it to the dealer several times while under warranty, but you know how much good that was. They thought it was a vacuum problem, but that door is electric.

Richard