Installed Heater Treater blend doors (all 5), now having problems

[Lakatos]

In researching the blend door problem in Feb the forum's unanimous recommendation was to replace with HT doors. Do all 5 if you have it apart. At the time I didn't have the spare cycles to do the work so I took it to a shop (not dealer).

$800 + $250 parts later I had HT doors in my 06. Had to go back for recalibration once and afterwards they were all good.

Fast forward to Summer in Texas. I begin using the AC as the temps rose. I noticed four issues (never seen before).

Just so we are all on the same page:
-Freon was checked and confirmed to be to spec (also confirmed no leaks)
-fan clutch working
-Truck is the old school simple manual control (blower speed, hot/cold, vent mode) that covers both pass & driver side
-measurements taken with laser pyrometer
-control panel modes (blend door functions) work as expected
-I have read that the airflow over the evap core is in our trucks and will tend to provide cooler air to the driver and a lack of Freon will make the driver and passenger variance worse

1. Temp differential between pass&driver side top vents 5-20 deg different (passenger warmer). this is after running 30min at 65mph 75-95 ambient outside. Drivers side temp 55, pass 75. You can imagine the wife at this point...Effect is less when on recirc but still a difference.
3. air flow on the passenger side is much less than the drivers side. never thought to check it before since everything was cooling fine
5. when set to top vents (no recirc) and driving around town AC is cool. stop at stop sign AC is cool (ie, fan clutch working). take off from stop sign, interior blower speed increases, humidity goes up and temp goes up. drive for a few more minutes and all three drop back to normal again.
7. when driving with AC for a few hrs, the drivers side foot area is so cold I cant stand it.

I take the truck back to the shop that installed the doors and they blame the doors for not sealing correctly. Their recommendation is to remove the dash and pull the HTdoors and install factory doors. ($1100).

So, need your experience here guys. I have read plenty that the HT doors solve the problem. I am thinking the shop botched the install (although on paper the blend door functions all work which is confusing).

Thanks in advance and appreciate your collective knowledge on our trucks!

2006 3500 DRW 5.9L All stock except the HT doors (and tows like a beast)

 

[PWong]

1.Temp differential between pass&driver side top vents 5-20 deg different (passenger warmer). this is after running 30min at 65mph 75-95 ambient outside. Drivers side temp 55, pass 75.
Low R134a or blend doors.
2.air flow on the passenger side is much less than the drivers side.
Blend doors.
3.when set to top vents (no recirc) and driving around town AC is cool. stop at stop sign AC is cool (ie, fan clutch working). take off from stop sign, interior blower speed increases, humidity goes up and temp goes up. drive for a few more minutes and all three drop back to normal again.
AC cycling ON/OFF for some reasons: low R134a, restricted air flow through condensor and/or evaporator. Don't know why would blower speed increase by itself.
4.when driving with AC for a few hrs, the drivers side foot area is so cold I cant stand it.
Cold air comes out from floor, blend doors

 

[Shadrach]

Have you contacted HT themselves? David

 

[Blue Ox1]

I just took my air box apart again after installing heater treater doors 6 months ago and they worked great,but upon diss-assembly found that the foam that the doors were wrapped in was unfolding and could of been restricting air flow.So before I re-assemble I will make sure to get some get liquid adhesive and reattach the foam on the doors.Not all of mine were doing just a couple of them,just a possible fix for ya maybe nothing at all .

 

[GI Joe]

I recently saw a thread on the HT doors having issues with their foam separating and causing obstructed flows.... Not sure what site that was on.....(maybe here?)...
Luckily(knock on wood) mine are still in working order...