hvac blend door

[bigwhitedog]

I noticed my 2002 a/c was not a cool as it should be last summer. The a/c checked out ok and what it seemed to come down to was the blend door was not closing all the way. Not surprising considering all the french fries and other crap that has fallen in the vents.



When I looked in the shop manual it says you have to pull the whole dash to get to this thing!!! like a 12 hour job. Does anybody know a sneaky way to get access to pull out the fries old pens and other crap without pulling the dash?

 

[StephenBailey]

Heatertreater.net has good information on diagnosing as well videos, and sells what looks to be a high quality replacement parts. Hopefully it is the recirculation door. It looks like there is a chance you could have a new style plenum box. They say 2002 was a changeover year. If you luck out and have the new style, the door can be replaced for around $18 through the glove compartment opening and fan opening. The new style door is available from RockAuto and Geno's Garage. There is good documentation of this process elsewhere in this forum too. The repair can be done on a 2006 in a couple hours by a non-mechanic (ex. pharmacist). The new door I used didn't look any better than the one I replaced and I expect to have to do this again periodically. The new plastic door has lasted over a year now.

 

[TGVET]

I noticed my 2002 a/c was not a cool as it should be last summer. The a/c checked out ok and what it seemed to come down to was the blend door was not closing all the way. Not surprising considering all the french fries and other crap that has fallen in the vents.



When I looked in the shop manual it says you have to pull the whole dash to get to this thing!!! like a 12 hour job. Does anybody know a sneaky way to get access to pull out the fries old pens and other crap without pulling the dash?

Multi-function switch and the heater BS are just a couple of the reasons I will never buy another Dodge. I do hope your fix is the easy one if not, as is with mine, you too will be ****** off after watching both videos on what it takes to fix the "engineered to fail" design with Dodge. DON'T even think about taking it to the stealership either unless you're really a glutton for future misery. Further explained in the video.

 

[Prairie Dog]

Dealer fixed mine when it was new and the fix has held but then again, I only have 71K on it. The down side is I got a rattle from their fine work that I've never been able to find.

 

[TGVET]

Dealer fixed mine when it was new and the fix has held but then again, I only have 71K on it. The down side is I got a rattle from their fine work that I've never been able to find.

First problem occurred at around 100K the Multi F@#$%ion Switch went out, wipers have a mind of their own, swipe the windshield at times even when off. Next was the heater issue which is the blend doors. Next was a 1-1/2" long piece of retainer ring in my trans pan at about 200K. 280K now and still running good. I'm going to fix everything myself per the video this summer, til then I just wedge the flap so my feet don't freeze.



Consider yourself lucky ?? if all you have is a rattle from the stealership. I have horror stories from years ago with my 95 K2500 Suburban 6. 5 TD which I was able to get 476K out of before the #2 cylinder intake valve rim chipped of. Other than that the stealership issue refers to the MFS and they cutting into my airbag wiring which didn't show up for months afterward. Then it was discovered that the wire had been clearly notched with wire cutter almost all the way through. Only other issue was a new trans needed which warranty covered. Needing a vehicle to drive ASAP I decided on the Dodge as I had heard many good things over the years. If I get 476K out of it with no other problems I may change my opinion on Dodge.



I take meticulous care of my machines as I don't have a money tree to just go out and buy a new rig whenever or pay some mechanic to ruin them.



Good luck with your 02 w/only 71K. My rigs are daily drivers usually 150 round trip.

 

[Prairie Dog]

Yea, actually it's an 03 but luckily I've been able to keep it at home the last few years and mostly use it just for camping and other fun stuff. It took 18 months to put 5k on it before the last oil change!

 

[rscurtis]

HVAC problems are not a Dodge exclusive. Certain F-150's have the issue also. Having said that, I'm going to tackle the recirc. door tomorrow.

 

[Shadrach]

Check out Auto replacement part, blend door fix, Heat, AC replacement parts and you will see that other vehicles have the same problem. It's not just Dodge. Shadrach

 

[bigwhitedog]

hey thanks !!

The tip on heatertreater.net is great. I have to go out in morning and see if I have the early or late design, but looks like a good solution. Much better than having to tear apart the whole dash etc.



Thanks

 

[TGVET]

The tip on heatertreater.net is great. I have to go out in morning and see if I have the early or late design, but looks like a good solution. Much better than having to tear apart the whole dash etc.

Thanks

I spoke to the gentleman at length who made the video several months ago when I discovered my problem. He is extremely knowledgeable on the topic and on vehicles in general and explained how the dash assembly is installed at the factory. It's not meant to just simply be plopped out and reinstalled. All the intricacies involved in removing the dash are shear nightmare. There's a plethora of possible problems getting it all back in and if prairie dog is only suffering a rattle he's lucky that's all it is.

Perhaps GM did something different with the heating design, my Sub is loaded with every extra, front and rear HVAC it was 10 years old and a daily driver, that's how I got 476K on it. In hind sight I wish now I would have immediately put in a 6. 6 LBZ and Allison transmission instead of spending over 45K for my NEW Dodge that I couldn't even get past two years without problems showing up, the first one being the Multi-F#$%#ing switch and the driver door seal as well.

I still need to put a new engine in my Sub which I really miss as it is in near mint condition stored waiting for a new power plant. Maybe a Cummin's which I will at least give credit for being a solid engine. So far. As for Ford, never owned one and never will.