Defrost door stuck again - after TSB done

[Blakers]

Well my defroster door is now sticking again after the TSB 24-004-03 was done over a year ago. It has worked fine until recently.



It's stuck with air coming out the dash vents only - no defrost or floor heat.



Any suggestions? Its got almost 70,000 miles and well out of basic warrantee.



Do you think the dealer that did the work before will stand behind their work and fix it again for free?



Has anyone fixed his own? Could it be something different?



Here's an old thread about this http://turbodieselregister.com/forums/showthread.php?t=116973&highlight=defroster



Thanks,

Blake

 

[DPKetchum]

Dealer and D. C. should jump into it again. JUST beware IF something like a pen/pencil or off the wall depris is found it might be on the owner. BUT if its failed due to parts or workmanship usually it WAS NOT a problem on a repair that had beed performed under warranty etc.

 

[Tony T.]

Blakers I would be curious to find out myself the results you get from the dealership on backing up their repair. I also had the TSB done last year, and so far it has worked fine on all settings. I had heard the new part they use, I believe acuator door was suppose to be of a better design than original. So far your the first one I've read about having problems with it sticking after having the TSB done. Keep us posted on your results.



Tony

 

[FOXY005]

I will jump in here... ... ... had mine done for the 3rd time, the second time they tell me there are 2 accuator doors and the second one broke this time they kept the truck for a week to work on it. Not sure about that 2nd door, someone who knows this Dodge HVAC system can chime in here ????



Fortunately I got a loaner but it was a Stratus, not quite the same thing.



Now the dash is starting to show signs of abuse from being taken out at least twice or more who knows how many times, several scratches and large scuff marks on dash... big scratch on floor shift & scuffs on door panels.



I am starting to think my truck is the practice model for novice mechanics.



Oh yeah let me mention that they have to take the whole dash out to replace the accuator door, Hang the engineer that designed that by the XXXX !



It worked for a week.



The third time they say the mix valve (the switch with the knob that changes where the air flow goes) was bad, they replace it I pick up the truck and same problem ..... they said they received a recall the next day that the new switch they recieved was defective and recalled.



Dont they check these things before they call and say "Your Truck is Ready to Go"



Another week or so goes by and the new switch comes in.



In for replacement again.



Actuall I guess this makes No. 4 they replace the switch again and so far so good, but its only been 3 months, if it goes again I think I will go to the Service Dept. and go Ballistic. :-{}



I think I better look around for another Dodge Dealer Service Dept.



Any of you guys have a suggestions for a "GOOD" Dealer Service Dept. in my area would it would be greatly appreciated.



My Location: Nazareth, PA



Note: The Dealer I bought it from and have it serviced by is not in the inmmediate area.

 

[Blakers]

Does anyone have a scematic or drawing of the heater assembly? It looks to be directly behind the glow box and radio and those parts snap off. Where is the def-heat-vent control valve located in the heater assembly? What acuates it - electric or vacuum?



Has anyone had success in fixing this problem themselves?



I will call the dealer, but wanted to ask these questions first.



Thanks,

Blake

 

[DPKetchum]

Know its electric. No vacumn in the dash anywhere anymore.

 

[Tony T.]

I will jump in here... ... ... had mine done for the 3rd time, the second time they tell me there are 2 accuator doors and the second one broke this time they kept the truck for a week to work on it. Not sure about that 2nd door, someone who knows this Dodge HVAC system can chime in here ????



Fortunately I got a loaner but it was a Stratus, not quite the same thing.



Now the dash is starting to show signs of abuse from being taken out at least twice or more who knows how many times, several scratches and large scuff marks on dash... big scratch on floor shift & scuffs on door panels.



I am starting to think my truck is the practice model for novice mechanics.



Oh yeah let me mention that they have to take the whole dash out to replace the accuator door, Hang the engineer that designed that by the XXXX !



It worked for a week.



The third time they say the mix valve (the switch with the knob that changes where the air flow goes) was bad, they replace it I pick up the truck and same problem ..... they said they received a recall the next day that the new switch they recieved was defective and recalled.



Dont they check these things before they call and say "Your Truck is Ready to Go"



Another week or so goes by and the new switch comes in.



In for replacement again.



Actuall I guess this makes No. 4 they replace the switch again and so far so good, but its only been 3 months, if it goes again I think I will go to the Service Dept. and go Ballistic. :-{}



I think I better look around for another Dodge Dealer Service Dept.



Any of you guys have a suggestions for a "GOOD" Dealer Service Dept. in my area would it would be greatly appreciated.



My Location: Nazareth, PA



Note: The Dealer I bought it from and have it serviced by is not in the inmmediate area.

Do you have the duel control settings for driver side and passenger H/AC. When you mentioned having two acuator doors I assumed you had the duel control. I just have the standard or single control.



That is a bummer on them having to go in so many times in the dash, your right the whole dash has to come out and I was dreading that big time because I just knew I would be hearing all kinds of rattles and squeaks from the dash afterwards. Luck has though mine was put back solid no,rattles or squeaks yet in nearly a year.



Good Luck with yours.



Tony

 

[DPKetchum]

Whatched a GOOD tech do one of those TSB's on the defrost door. LESS then hours from start to finsih. Did not remove dash. Just pulled it back enough to gain access. Never could tell it was touched. Even butts in ashytray wern't didturbed. Now he did pull WHOLE dash to replace a heater box. Dash was out in 30 minutes. Its only got a few plug ins. Its really not very difficult. Its NOT the dealer. ITS THE TECH who's working on it.

 

[FOXY005]

TONY T



I do not have the dual control system.



DPKetchum



I am sure you are right about the Tech.



The first time I could not tell they had the dash out, unfortunately that Tech. moved on to greener pastures.



The second time the Service Manager kept telling me how much trouble the tech was having and what a "BEAR" of a job it was.

 

[DPKetchum]

Its actualy pretty easy. It would be a BEAR if a FIRST time or a real novice. Bet a evoperator assy pays about 3 hours or so flat rate.

 

[Blakers]

I just called the dealer that did my original TSB 24-004-03 repair and they will not cover the repair for free. They want me to bring it in and look at it for $65. 50/hr to see if that is even what is wrong. And then charge me from there.



If I could tell where this potentially stuck actuating arm is located, perhaps I could look at it and see what is up. Can it be reached to feel it?



If the arm is not stuck or broke, perhaps it is the switch selector. That I could change and I get a discount on parts at the dealer where I bought it.



Thanks guys.

 

[Blakers]

Where's the best place to get a service manual? Anyone have a used one?

 

[DPKetchum]

Thats not right. Call D. C. !!!! 1-800-992-1997

 

[Blakers]

Still researching...

Guys, I'm still trying to figure this heater problem out. What symptoms did yours have when it was not working? Did you have floor heat, dash heat, or defrost? Or all or none? Or what combination?



Mine is just dash heat. It won't come out of the defrosters or the floor vents. According to the manual I obtained, it apears there's an air valve for the defrosters and one for the dash (panel). If there is no air coming out except for the panel, would not two air valves have to be stuck? The one for the panel and the one for the defrost? If my thinking is right, this would be highly unlikely for two air valves to stick.



I'm thinking, is it more likely that this is a problem in the switch?



Ideas?



Thanks,

Blake

 

[Blakers]

Here's the drawing... .

 

[Blakers]

Update...



I took my truck into dealer where I bought it (Classic Dodge in Madison, Ohio) and after $47, they told me they could pull it all out and replace it for $850! No warranty and they won't do anything about the TSB.



So tomorrow I will call DC and go from there. Probably end up paying for this, even though they must have put a defective part in when they replaced it before under warranty.



Blake

 

[Tony T.]

Update...



I took my truck into dealer where I bought it (Classic Dodge in Madison, Ohio) and after $47, they told me they could pull it all out and replace it for $850! No warranty and they won't do anything about the TSB.



So tomorrow I will call DC and go from there. Probably end up paying for this, even though they must have put a defective part in when they replaced it before under warranty.



Blake

I believe I would do the same on calling DC especially since you did have it repaired before under the TSB. That $850. 00 repair seems awfully high to me, the dang part probably only cost $10. 00 bucks. I would raise some stink with DC first before I had to pay $850. 00, that's ridiculous. Good Luck.



Tony

 

[Bob4x4]

Most dealer repairs are covered 12/12, reman assy's are 3/36. Tsb's are for info only. not authorization for repairs. Good luck



Bob

 

[DPKetchum]

If it was repaired UNDER warranty and repaired because of the TSB I think the dealer(D. C. ) should have a look see to see what failed. ONE its a KNOWN problem and TWO they have been in there before. Service manager has the AUTH. from D. C. to warranty such again with previous repair paper work to back it up etc. They(dealer) at this time does NOT know what failed. Its only a couple of hours labor to ease dash back and see excatly what has failed. I've been in that same situation MANY times and think thats how I would be handling the situation.

 

[Blakers]

I called DC today and explained the situation to them. After being on hold, passed around to someone else for a while, and one lady calling the service manager at the dealership, it looks like I might be in luck. She said she has to wait for the dealer to get back with her, but she will call me Friday morning and let me know for sure. She thinks they will cover it with a rather small co-payment.



If anyone has a heater housing that has been removed, I would like to see it. Or one of us should look it over good and find out what really goes wrong with these. Do the doors just stick shut? Or does the shaft that the door pivots on break off? If a door was simply stuck, and one knew where to do it, couldn't they just drill a small hole in the plastic and push the door open with a welding rod or something small?



I'm just trying to think of a simple solution for someone who is not covered under warranty and doesn't have the time or money to fix it now. Even if one had to wedge a rod or wire into the door to get it to work for a while.



Anyone think about this?



Thanks