Blend door problems in which the plastic rods strip out?

JOSHPROPLUMBING

MEMBER
2003 DODGE DURANGO
4.7L
V8
4WD
70,000 MILES

I'm looking to buying the vehicle listed above and I am wondering if they have the same damper/blend door problems as the Ram of the same year. I own a 2002 and a 2003 dodge Ram 1500 and both have blend door problems in which the plastic rods strip out and cause uneven air flow and temperature from the ducts. The repair requires removal of the dash and I don't have time to do it. I don't want to buy another similar vehicle with the same problems. Also, the dash on the Ram models cracks and breaks in an unrepairable way I'd like to avoid this as well. Thank you.

Friday, August 19th, 2022 AT 4:44 AM

1 Reply

KEN L

MASTER CERTIFIED MECHANIC
51,582 POSTS

Yes, most Dodge vehicles have this problem, it is a design flaw. Here is how to repair the problem:

REMOVAL
The dual zone heating and air conditioning system is equipped with two blend door actuators.

1. Disconnect and isolate the battery negative cable.
2. Roll the Instrument Panel Assembly back.
3. Remove the HVAC unit from the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation,

4. Remove the blend actuators.
5. Remove the drive shaft from the blend door.
6. Remove the upper half of the HVAC housing.
7. Slide the blend air module out of the HVAC housing.

INSTALLATION
1. Install the drive shaft to the blend air door.
2. Install the blend actuators to the distribution housing. Tighten the mounting screws to 2 Nm (17 in. Lbs.).
3. Connect the HVAC wire harness connector for the blend door actuator to the actuator connector receptacle.
4. Roll the Instrument Panel Assembly back into position.
5. Connect the battery negative cable.

Check out the diagrams (below). Please let us know what happens.

Image (Click to make bigger)