heat woes --need heater guru

[bucket1]

2001 4x4 qc 140,000 mostly stock --ok have had the old girl 7 years this winter not much heat. So checked theremostat ok replaced any way running around 190. flushed heater core good flow(always change anti freeze with distilled water) dropped blower vacumed nothing in there. truck is mantained very well and i didnt expect any thing in there. changed blend door acuator and coupler it worked the same as the old one. it moves through the ranges ok. So when i had it out i lubed the door and manually moved it . you could here it shut each way or i thought it did. only thing is there was a little slop in the shaft. i read on one thread that when the actuator feels pressure it stops . i was wondering if a little binding was making it stop. drive 160 mile a day so no air in the system. I m going to drop the blower this weekend and stick the digital camera up the hvac rectum and try and take some pictures of the door and coils to see if any fod is lodged in there. I realy didnt like the price of a new heater controll from the ******* . So any one with ideas let me know. i think if the blend door is broken then i will do some bombing with dremel and roto zipp cause there is no way i am going to tear the dash off to fixed that little plastic sob.that some overpaid enginer developed to save money. Also pondering why none of the big three put an access door in the truck bed to get to the fuel pump in the tank?