Help please! 68 Dart Heater Control dilemma

Section 1-2 in the factory service manual (Free download from my Mopar.com) has a procedure but it uses a tool no one has.

The first thing I would do is remove the cables from either end, (which ever is easier to remove and check for free movement of the cables.

Once free movement has been established manually check that each door is opening and closing easily and completely.

Then make sure each control lever is moving easily and completely.

Once all that has been established, re attach the cables to the control and adjust the outer part in it's mount till you have propper function.

There is a possibility that something inside the heater box (old foam for instance) has come loose and is preventing the door frop opening or closing correctly.

I find on my 67 dart that the upper control does not sit all the way to the left. I probably could adjust the cable more but I got it better than it was so I left it alone

As for the pins, you could get a speed nut to keep the cable on the crooked pin.
Are your pins intact and look like this?

If the tapered top part is broken off that could be part of the reason the cables are popping off.
View attachment 1715976855

Hey Dana... Thanks sooo much , your kind feedback is most appreciated!
My pins are exactly like those in your pic! The pin closest to the driver's side seems to have lost one of its split top pieces... I have somewhat checked some of the items you suggest, but will re-check them all as you've instructed, meticulously to see if I can improve the situation, thanks again