Attention: TDR Forum Junkies 
This (and other) threads helped me figure out the problem & solution (I hope!).
So maybe this will help someone else.
**FYI** - if you suspect the blend door problem, test your temp/s with an A/C thermometer (available at any parts store - looks like a tiny "meat thermometer" on a stem about 4" long).
I failed to do that the first time in to the dealer - they didn't do any "repairs" except on paper.
(I had about 4 days left on the 36K factory warranty for my '05).
Caught the problem on a VERY hot day, with the wife in the truck. My side nice! Hers, not!
It was a cool day when I dropped it off and when I picked it up - even rained later, so didn't catch the (nothing fixed) for a day or two. Brought it back a week later.
(And - yep, had a thermometer in my garage tool box).
Check the temp on the driver's side, then the passenger side.
For me - there was about 20 degrees difference - 42 degrees on driver's side. 62 degrees on pas side.
Told the service rep that - pretty hard to dispute, so no hassle.
Here's their write up (spelling errors are theirs):
"Customer states the AC is not cold on right side of dash. Passenger blend door is partially stuck open. Removed dash. Discharged A/C system. Removed evaporator housing out of vehicle. Inspected and found all 4 door in heater case an D panel mode doors have been loosen by wearing hinges. Discharged A/C system. Removed dash and evaporator housing. Replaced heater case with 4 blend doors. Replaced mode door (panel door). Reinstalled everything. Recharged system with dye. Calibrated all doors. Tested A/C performance. "
(End)
No charge for repairs. Both sides seem to be cooling the same now (by thermometer - about 42 degrees).
However, the outside temp was only about 75 degrees.
PITA for the time they had it (one week) - two parts were back-ordered.
Only have driven it about 10 miles - so the jury is still out on how long repairs will last.
JC
So maybe this will help someone else.
**FYI** - if you suspect the blend door problem, test your temp/s with an A/C thermometer (available at any parts store - looks like a tiny "meat thermometer" on a stem about 4" long).
I failed to do that the first time in to the dealer - they didn't do any "repairs" except on paper.
(I had about 4 days left on the 36K factory warranty for my '05).
Caught the problem on a VERY hot day, with the wife in the truck. My side nice! Hers, not!
It was a cool day when I dropped it off and when I picked it up - even rained later, so didn't catch the (nothing fixed) for a day or two. Brought it back a week later.
(And - yep, had a thermometer in my garage tool box).
Check the temp on the driver's side, then the passenger side.
For me - there was about 20 degrees difference - 42 degrees on driver's side. 62 degrees on pas side.
Told the service rep that - pretty hard to dispute, so no hassle.
Here's their write up (spelling errors are theirs):
"Customer states the AC is not cold on right side of dash. Passenger blend door is partially stuck open. Removed dash. Discharged A/C system. Removed evaporator housing out of vehicle. Inspected and found all 4 door in heater case an D panel mode doors have been loosen by wearing hinges. Discharged A/C system. Removed dash and evaporator housing. Replaced heater case with 4 blend doors. Replaced mode door (panel door). Reinstalled everything. Recharged system with dye. Calibrated all doors. Tested A/C performance. "
(End)
No charge for repairs. Both sides seem to be cooling the same now (by thermometer - about 42 degrees).
However, the outside temp was only about 75 degrees.
PITA for the time they had it (one week) - two parts were back-ordered.
Only have driven it about 10 miles - so the jury is still out on how long repairs will last.
JC
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