Ok so I have some heat but when its less than 20°F I can never get warm!

I did flush the heater core and both heater supply lines are hot so I know its not the heater core

I also replaced the thermostat just to eliminate that...

I had someone put a bore scope down the vent and he witnessed the blend door not closing all the way, it attempt's to move but does not do its job.

Is is my moms 2002 KJ and I don't have the jeep long enough to tackle dash removal at this point.

Can I drill a hole in the heater box and manually close the blend door? Where can I drill the hold to accomplish this?

Any help will be greatly appreciated

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-05 Dark Khaki Limited CRD. GDE ECO tune. In-tank lift pump, Transgo doo doo kit, B&M trans cooler, replaced trans solenoid pack and filters, Newer Michelin tires, Timing belt with all related parts replaced at 110,000miles.

How about replacing the blend door motor,it's electric and easily replaced on a KJ.The door itself not so much as the whole dash has to come out then the HVAC box can be removed.

I have the same problem on my 02 Liberty with no heat. Still trying to find where to cut a hole in the heater box to get to actuator, but no luck. I can hear the actuator trying to move but it's not opening completely.

I have had the hvac controls, radio, glove box, and blower motor out.
Where the heck is the blend door motor at?

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-05 Dark Khaki Limited CRD. GDE ECO tune. In-tank lift pump, Transgo doo doo kit, B&M trans cooler, replaced trans solenoid pack and filters, Newer Michelin tires, Timing belt with all related parts replaced at 110,000miles.

Look at where the heater core lines pass through the firewall,should be on top of the HVAC box farthest away from the firewall in line with the heater core lines.

Thanks for the help, I will give it a try.

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-05 Dark Khaki Limited CRD. GDE ECO tune. In-tank lift pump, Transgo doo doo kit, B&M trans cooler, replaced trans solenoid pack and filters, Newer Michelin tires, Timing belt with all related parts replaced at 110,000miles.