Has anyone replaced the A/C distribution housing?

KKomodo · **Posted:** Tue Jun 09, 2015 3:07 pm

Long story short I believer my blend doors are jammed in the housing. I can't turn the blend door by hand and the gears are messed and have to tape the defrost/feet door up to not be stuck on defrost. The blend door for the face is stuck and won't move. So has anyone replaced the whole housing before?

ajohns1288 · **Posted:** Tue Jun 09, 2015 9:49 pm

Did you take the plate the actuators are screwed to off as well? Mine would only blow on the face because an arm popped out of the track, which looked like it jammed the linkage. I took the plate off and the cam/arms fell apart but the gears for the doors turned fine. All of the pieces still work but the problem is getting it back together, which is where I am at now.

KKomodo · **Posted:** Tue Jun 09, 2015 11:09 pm

Yeah that was an on going problem since I got it. What I figured had happen again, but this time no. The 2nd blend door is stock and will not move. So I only have defrost or feet. Which feet it is and I had to tape it up there cause it would not stay since the gears are out of align, and the one is frozen frozen.

Scar0 · **Posted:** Wed Jun 10, 2015 6:11 am

Pull the radio bezel off, remove the radio, then you should be able to remove the center panel vent tubes. Through that hole you will be able to reach the mode door. The blend door is for temp control.
If you look from the drivers floorboard up and toward the firewall, you should see the blend door actuator with a plug going to it, the mode door actuator is higher up and closer to the fire wall.
When the mode door actuator(2 screws), blend door actuator(2 screws), the driver side front floor duct(2 screws), and the actuator mounting bracket(3 screws) are removed, you should be able to get to the defrost door lever and gear assembly, mode door cam, and panel door gear.
It will be tight going working under the dash, but maybe you can find out whats going on with everything exposed.
This is the best How-to I've seen. It is for a KA but the KK is very similar, if not exactly the same.

KKomodo · **Posted:** Thu Jun 11, 2015 10:10 am

Scar0 you are the best. I was able to get to the jam from the top there. Have it rigged now till I can order the new side plate and gears. Thank god I don't have to take the whole :furious:

thing out. As always hood help from the lost group.

ajohns1288 · **Posted:** Thu Jun 11, 2015 9:06 pm

I just finished putting it back together and its working perfectly. I got a couple pics that should help anyone else in the future, I'll post them later. If you're looking for the gears and such, I believe they are serviced with the air distribution housing if you are getting the mopar part.

Scar0 · **Posted:** Fri Jun 12, 2015 1:40 am

KKomodo wrote:

Scar0 you are the best. I was able to get to the jam from the top there. Have it rigged now till I can order the new side plate and gears. Thank god I don't have to take the whole :furious:

thing out. As always hood help from the lost group.

Cool deal! Happy to lend a hand where I can.
You may see if one of these comes with the gears etc, 2 part # same Pic in the parts catalog
PLATE, Actuator Mount
68004009AA

68004034AA

If not then maybe a junk yard to avoid the cost of the whole housing.

ajohns1288 wrote:

I just finished putting it back together and its working perfectly. I got a couple pics that should help anyone else in the future, I'll post them later. If you're looking for the gears and such, I believe they are serviced with the air distribution housing if you are getting the mopar part.

Glad you got things back together! :BANANA:

Pics are always welcome.

ajohns1288 · **Posted:** Fri Jun 12, 2015 8:13 pm

Here's a quick writeup I put together showing the actuator linkage as well as the way to get the vents off. I would have taken more pics, but I was too busy making sure the linkage stayed on because of how frustrating it was to get it lined up.

viewtopic.php?f=104&t=82363

Has anyone replaced the A/C distribution housing?

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