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 Post subject: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Fri Jun 12, 2015 8:10 pm 
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There are a few other topics on this issue already here. I went though and snapped some pics as I went, so hopefully these will help someone.

This how-to assumes you already know you have an issue with the mode door linkage, either the door is stuck or the linkage popped off the track. Refer to the following how-tos for more info:

Blend Door Actuator diagnostic & fix - KKomodo & Scar0 - viewtopic.php?f=88&t=76917
Blend Door Actuator Motor replacement - joeS - viewtopic.php?f=88&t=72544
Center Dash Bezel (around radio) removal - Diggerfreek - viewtopic.php?f=104&t=36253

1: Remove drivers side knee bolster, kick panel (2 scrivets), center bezel, and radio (4 philips head screws)

2: Remove blend and mode door actuators. (4 T20 screws)

3: Remove actuator shield (3 T20 screws)
Image

4: Remove mode door actuator linkage if it didn't fall off
Image

5: Remove center vent (3 philips screws) and stick hand down to reach door. Try and move it to get unstuck.
Image

6: Try to turn the two gears on the side of the HVAC housing. if they turn freely, you're good.

7: Put the smaller/lower of the two white arms on the housing, be sure to mesh the big tooth on the gear to the slot in the arm.

8: Put the bigger/upper arm into the outer track of the cam (spline side out). Carefully move the assembly into position and place the cam on the housing. Make sure the lower arm goes into the back slot on the cam and the bigger arm meshes correctly with its gear.
Image

9: Carefully put the shield back on, wouldn't want to knock of the actuator we worked so hard to align. Do not test the linkage until the shield is back on. They will fall off and you will get angry. :furious:

10: Once the shield is back on and tight, move the linkage by hand to make sure it moves freely. If so, you can put everything back together, if not, you'll have to take everything apart and make sure the linakge is put together right. :banghead:

11: If it still doesn't move, chances are something is very broken. You'll probably need either new linkage parts or a new HVAC housing.

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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Fri Jun 12, 2015 8:26 pm 
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Nice write up!

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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Fri Jun 12, 2015 9:00 pm 
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Fantastic Job! This is an issue that seems to be cropping up on more and more KK's as they age. Glad to have the how-to for reference in case it happens to mine.

P.S. Added this to the How-To's Index. :mrgreen:

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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Thu Jul 14, 2016 10:26 am 
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This is exactly what I was looking for. Thanks!


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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Sun Sep 11, 2016 2:07 pm 
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Great job. Thanks for sharing this i was looking for such kind of information.

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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Thu Feb 02, 2017 11:30 pm 
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Is this the reason why I would have no air flow coming out of floor vents?


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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Tue Jul 25, 2017 8:58 pm 
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I need the diagram of the lower gear placement for actuator below in picture


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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Sun May 06, 2018 6:13 pm 
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Well, I think the unthinkable has happened. After hearing a loud *POP* the HVAC mode is stuck on feet.

Image

I took this photo after removing the mode door actuator. The actuator seems to work fine. The big black gear on the HVAC distribution box seems broken though. You might have to zoom in to see it, but it looks shattered.

So, is a new HVAC distribution box and a complete dash disassemble in my future? :POPCORN:

The distribution box (#8 in the diagram):

Image

Link to it: https://www.factorymoparparts.com/oem-parts/mopar-distribution-box-68004022aa/?c=Zz1odmFjJnM9ZXZhcG9yYXRvci1hbmQtaGVhdGVyLWNvbXBvbmVudHMmaT1URzA3MDg1NSZyPTgmYT1qZWVwJm89bGliZXJ0eSZ5PTIwMDgmdD1zcG9ydCZlPTMtN2wtdjYtZ2Fz

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Trailer build thread: viewtopic.php?f=72&t=77997


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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Sun May 06, 2018 6:48 pm 
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https://youtu.be/o-WoL0xRicU

Video explanation of why this happens and what has to be done to fix it.

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Trailer build thread: viewtopic.php?f=72&t=77997


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 Post subject: Re: HOW TO: Fix stuck HVAC mode door\actuator
PostPosted: Mon May 07, 2018 4:12 pm 
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After watching some YouTube videos about dash disassembly for heater core replacement (since the heater core is inside the distribution box that needs replacing), I think I’m going to save up and have this done professionally. The A/C compressor is beginning to fail also (unrelated but also expensive) so I’ll try to get those jobs done at the same time, later this summer.

A good dash removal video:

http://www.youtube.com/watch?v=-6qfLs1ge5Q

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Jeepin By Al 4" Lift Kit
Goodyear Wrangler Duratracs 245/75/R16
Full MOPAR skid plates
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AtTheHelm Front Recovery System

Trailer build thread: viewtopic.php?f=72&t=77997


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