Another blower issue..

[Zcubed]

yes sounds like the gears on the Hvac are faulty or have become jammed
you need to remove the glove box and and see how they move

Took the glove box out and run through the 3 three air vent position buttons.
As you said could now see the workings.
Sometimes the mechanism seemed to move freely and on other times it seems to jam and gears would chatter, and probably didn't complete its travel, which would explain why sometimes vents don't close fully.
Bit hard to see which bit is at fault, looks like a bit of a pig to get at it.