The difficulty of the green (defroster) actuator is grossly overrated. Yes, the pod needs to come out, but it's very easy to get to after that. IMO, the recirc is the worst.

 

FWIW, I got to tackle this one over the weekend, and came up with the following to get that screw started. 8mm socket, u-joint, 6" extension. The magnet lets the socket turn but holds it in place. A weak magnet would be better still. Then to turn the screw once started, an 8mm gearwrench, with an angled pick in the other hand to keep pressure on the screw head while ratcheting. 1 tooth at a time....

 

Does the pod have to come off for our airbag equipped cars?

 

Answer is no.

As for references to the 5mm washer for the two 8mm bolts that go through the console into the dash here's a picture.