Re: Passenger side Blend door gear replacement
The driver side is a bit more cramped due to the metal heater core lines being routed very close to the HVAC sub assembly and the actuator. There is also the plastic plumbing for the floor vent, which splits into 2 halves that also needs to be removed to gain some access room. I'd suggest performing the repair on a cold engine.
On my 2011, I had to replace the passenger side gear twice and the driver side once. I see quite a few passenger side gear failures. Driver side is not as common.
2014 WK2 Overland - Billet Silver