You're right.
Tore everything apart again and the foam is coming off and the issue is with one of the doors. Those flaps are way up in the dash. Not worth to handle at the moment.
Must have been happening for awhile and I didn't notice. Going to leave as is and get to this when other issues arise.
Just cleaned out my blower motor and evaporator box. Upon placing everything back together I noticed a "clunk" noise when changing from outside air to recirculate. Only in this direction do I have the issue, not the other way around.
Linkage does not appear to be rubbing on anything. AC Blows...