Chrysler Repair Questions? Ask a Mechanic for Answers ASAP
Yes you will have to remove the dash to access the blend door workings. and yes it is a bit of a time consuming job.
while you are at it i would recommend replacing the heater core since it is a large job and you have to disturb the core when servicing the box.
The doors should all move with little resistance when the actuator is removed. that rod is probably not going in because its a little off alignment when trying to insert it back through the door or there is a sort of a snap clip that will just use a bit of extra pressure when popping back in place.
make sure the door problem didnt damage the actuator, as they are all plastic and strip easily.