Im going to guess your truck is a gm product? They are bad about breaking the flap and yes the whole dash usually does have to come out. Which sucks.
My Tahoe has problems with one of the blend door actuators - well, two if you count the rear AC. I've pulled those damn things out a few times. What a PITA. I've gotten a bit better at it now... in the back, I just pull it apart twice a year and swap it from hot to cold and back.