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Joined: Sat Dec 20, 2008 6:02 pm
Posts: 499
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.

Unfortunately the blend door and its actuator is not accessible without removing the dash. The actuator is on the top of the HVAC housing and connects to a linkage, maybe if your lucky you can get to it through the glove box but I'm not sure.

From Chrysler

The blend door actuator is a reversible, 12-volt direct current (DC), servo motor which mechanically positions the blend-air door. The blend door actuator is located on the top of the HVAC housing.

The blend door actuator is contained within a black molded plastic housing with an integral wire connector receptacle and three integral mounting tabs that allow the actuator to be secured with three screws to the HVAC housing. The blend door actuator also has an output shaft with splines that connects it to the linkage that drives the blend-air door. The blend door actuator requires mechanical indexing to the blend door linkage.

REMOVAL

WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

NOTE: Prior to performing this procedure, turn the ignition key to the On position and set the A/C-heater control in the mid-temperature position and wait 10 seconds.

Remove the instrument panel from the vehicle (Refer to 23 - BODY/INSTRUMENT PANEL - REMOVAL).
Remove the three screws that secure the blend door actuator to the top of the HVAC housing (Blend Door Actuator -LHD shown, RHD smiliar).
NOTE: Note the actuator shaft position for installation reference.

Remove the blend door actuator from the HVAC housing.

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03 KJ - OME 927/948 - 3 ring clevis - 1 extra upper per side

If you can get the Jeep for about 3 hours and you are pretty handy/confident in your skills.... you can get the entire heater box assembly removed/reinstalled... I was very hesitant to start this job before I actually did it... but once started it's not as difficult as one may think... Unfortunately it was freezing out so I couldn't take the time to take pictures and actually write up a how to... but I wrote a basic "how I did it" afterwards... http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=3&t=72219