Blend Doors and Evaporator Replacement - Part 2, Rebuild
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- เผยแพร่เมื่อ 9 ก.พ. 2025
- Part 2 (Rebuild) of a 3 part series detailing the process to properly rebuild the HVAC system of a 3rd generation (2003-2009) Dodge Ram with a new evaporator core and all 5 air doors without hacking the box apart and taping it back together. All air doors came from Blend Door USA and the evaporator core came from Four Seasons.
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im a 60 year old forty year certified tech.... loved this video no short cuts just great competent work explained well.... i just popped in a recirculation blend door without pulling the dash by taking out the heater motor and actuator and putting it in... but the defrost floor heat blend door is busted also so i will be asking my customer how far he wants to go and if he wants to put in the aluminum blend door kit looks like a great kit.... thanks for posting such a great video very well done...
after six years of this video I'm sure you know how much helpfull your videos is man , and IT DID HELP ME ALOOOOOOOTTT THANK YOU SOOO MUCH BROTHER ...
Thanks for the three part video this by far is the Best way to repair the HVAC for a Dodge truck.and the Best video on the subject. Thanks again for the help
Outstanding video. Thank you so much for such a thorough and informative video. Very helpful. Thanks
El mejor video para esta camioneta bien detallado lo felicito ya que voy a cambiar el evaporador y con este video me siento confiado gracias
Great VID! Thanks. I replaced all the doors in my dodge hvac system. Your videos made it really really easy. And helped decide on what brand of door to purchase. I went with Blenddoor. :) Thanks a million.
Just finished this. Appreciate the help, a lot! Saved me a ton of money. Some things to note. You can use a pick to release the connectors to the actuators when stuck. press down on the side of the connector facing the housing. You can buy a set up of picks and hooks at harbor freight for less than five bucks. WD-40 helped me remove the old gasket material.
Just pulled the hvac box on my 06 ram this weekend. This video made it possible. Thank you sir
Replaced the heater and evaporator core plus all blend doors with new weather stripping. This thing is like new and I could tell an immediate difference in the air pressure. Glad I watched this video before doing the job; I only had to venture to the store to get the AC line removal tool (my bad planning). Thanks for taking the time!
I hate those tools so much.I cut out my AC accumulator to get at the last one!
Great videos , Dodge should be paying you for these . I had to do the large door on passenger side air box when my 06 was about 6 months out of warranty . At that time there were no up-graded parts available had to purchase a whole new air box assembly and just use the door .
I have a 2008 RAM, 6.7l Cummins, manual transmission and your videos are by far one of the most useful, comprehensive and informative videos I have come across. Not only did you provide the source for replacement doors, but also any other possible detail needed. I can't express my appreciation for your effort. Thank you Sir! I was even able to find my question I have/had in the comment section. Although - if you don't mind me asking it again to maybe get a clarification on it. HOW is it possible that the door position and actuator do not need a certain 'alignment' when being installed? I don't doubt your reply to the question, I just can't picture it. This might change once I have taken it all apart, but I would like to be efficient without delays when it comes to the point of the truck being unusable. Again - Thank you taking the time and most effective video composition without any unnecessary rambling or bad video quality!!!
The actuators don't have and stops molded into them. They are simply a geared motor that will turn infinitely. The actuators change direction by reversing polarity on the motor. The truck detects a full stop by sensing an increase in resistance from the motor, then killing the power. It will turn until it cannot turn anymore, then stop. You can play with this by putting your hand in the housing and blocking the recirculation door. It will turn until it hits your hand, and then stop trying until you command another position change.
I see. Got it! Excellent. Looks like I will be going for it very soon. Very excited to fix the few little things. Really good website by the way. It is quite funny actually how similar our trucks are. DPF delete, goose neck hitch, even the same brand. I especially love the exhaust break mod! Absolutely love it! Again - Thank you for putting in all the work to make this known for everybody!!!
Great video. We didn't have to watch 30 min of turning screws, lol. Concise and to the point. Makes me wanna check your other content and possibly subscribe. Thank you
GREAT videos, can hardly wait to do this to my 06 over the winter.
This is an excellent video. This guy is very good at teaching and is very clear plus, the way they did the videos, very well done.
Great video just got mine back together this was very helpful. I been riding without air for 3 years and this video was amazing
The white driver is hard to get off. I tried for ten minutes before I had to leave to work. Good video. I’m using it to do mine. Got my metal doors today.
Simply the best how to video out there. Well done sir.
Nice job explaining this intimidating task! I’ll be doing it soon.
Best video I've seen on this so far. Most of the others have no lighting. Thanks.
Great video.
The Dodge HVAC system is a real Turd.
Instead of the weatherstrip he used I bought a 1/2”x1/2” expandable foam strip and used it. At first I thought a grave mistake in my purchase however you need to speed the expansion up with a bit of heat. After the heat I was pleasantly surprised at how close it was to the factory foam. It was at Lowes right near the MD foam he used and is also an MD product.
This is the BEST video. Very detailed. Step by step. AWESOME 😎. Thanks a lot. I'm sure your video will help to many people. 👏👏👏
very professional very detailed. I learned a bunch. even tho I don't have a ram. I was searching for durango. great video. thanks
If the recirculation door is broke and dropped down will u get any heat as of now just blowing a little warm . Neighbors 02 has very little heat if any. Best video I've seen yet on dodge. Hats off to u sir.. glad I own a chevy lol
Great tutorial.I am nervous about taking on this job. But determined to save money. I have a question......Do the doors have to be in a certain position, when installing ? Meaning.....do they get installed in the open, or closed position ? I'm not sure if the actuator corrects this. Thanks in advance
Thanks! Gonna help me a lot tomorrow at work !
So there is a total of 5 actuators? And are they all the same or are they all different? If so do you by chance have the part numbers for them
8 degrees outside had to drive 320 miles with frozen toes! cant wait to do this repair asap
6:04 Gave me the confidence to reassemble my dodge back after I got everything out for evaporator replacement. I was thinking I was gonna have to do it all over because the doors will not be in the right spot.
John, im currently experiencing passenger heat, driver cold air when the front heat mode in a dual zone 2016 2500 laramie is selected. Ive also noticed that my feet, defrost, and rear vents are all cold when selecting those and heat. A/C in all areas seems to work fine.
Thoughts on causes? I think i could follow your video to remove dash - i’d rather not yank the whole box out. Any ideas if i can solve the issue without a full disassembly?
You always have the option of cutting apart the box and going through the side, but I dont understand why people would do that. The box is super expensive to replace if you jack it up. The good news is if you replace all the doors the right way, you'll never have to go into it again for a failed door.
PHENOMENAL VIDEO!! Do new blend door actuators require programming or calibration?
So I’m looking to just replace the actuators I count 4?
Can the recirculation housing be removed without pulling the entire heater box on an 04 Ram 1500
Good job! My 2003 dodge 1500 has heat only on the passenger side and blows cold on the drivers side. Plus the fan only works on high
The heat only on the passenger side could be the heater core is half clogged up. What i did when my 03 Ram had that problem was backflush the heater core and then put the hoses back on the heater core opposite from what it was, meaning the hose that was on the top, put on the bottom of the heater core and vice versa for the other hose so the flow will be backwards in the heater core. Been having 140 degree heat on both sides for 4 years since i did it to my truck. The fan only working on high is the blower motor resistor next to the fan is bad, about a $30 part.
Chris Brown ok man thanks a lot! I’m gonna flush it this weekend and check up on the resistor. Man we got 2 feet of snow here In New Mexico
dorian james good gosh I’m in Louisiana so I don’t c that snow I get the heat during the summer
Many thanks for your quick responses to my questions. what do I put in youtube bar so I can see part 1 of how dash board etc is taken out and what I would have to do. Cheers .
Exact same title as this one, only with part 1 instead of 2.
where can I order the doors from and what is the correct name for them .AS always many thanks
Blenddoorusa.com
When you look up through the floor vent, you can see a mode door. Would you push the door up or pull in down for defrost?
Now the lower blend door that deflects the heat you said what is that plastic piece that is called on the lower defrost blend door cause it broke on mine and having troubles trying to find it
Hi John, Great video. I have a 2008 Infiniti QX56 that I am trying to get to the cause of a door/floor creaking sound. In other words, it's not a clicking sound of a broken gear in one of the actuators. I have watched so many videos and read the forums trying to find someone else with this symptom. One mechanic who was showing where some of the actuators were in the Infiniti thought maybe it's a problem with the actual door itself making the creaking. Have you ever dealt with something like this before? I didn't see you mention it here but I'll ask anyway....do these doors need to be greased? Have you ever had creaking actuators? Do the actuators need to have any parts greased? I was concerned that when my mechanic fixed a clicking actuator, he didn't bring the door and actuator back to base and the actuator is trying to move the door passed a stop point, hence the creaking. I'm thinking it's on the drivers side and is either the mode or defrost mode door. I'm praying it's not the one behind the dash on top of the heater box. Any insight you have would be greatly appreciated since I'm going to tackle this project in the next week.
Will the recirculation door and housing from a gen 4 ram 1500 fit a third gen ram 1500 so you can get cabin air filtration.
Awesome video!!! Love how you explained everything in such great detail. I have a 2003 dodge ram 3500 with a 5.7 in it, after this video I'll be tackling and upgrading all the blend doors to blend doors USA. Is my 2003 disassembly and reassembly the same being that it's a different Year and engine ? Thank you so much... Mike...
instaBlaster
Console removal is different but the dash is the same
Could a partially clogged heater core cause one side of the truck to have heat and the other not?
Im just trying to get parts ordered. Are all the actuator motors identical/interchangeable?
Such a good video. Thank you!!!! I cannot source new actuators; they're all on back-order...
very helpful and great videos working on 03 3500
Great vid. Time to rig the blend doors to full cold! lol
So how much you charger to fix my a/c
TY for the type of door explanation. I have a 2002 Ram 1500 and the plenum looks similar to the one in this video. The issue is the passenger side blows toasty air while the driver side blows mildly warm air, at best. All vents (defrost, front, and floor) show the same temperature difference. Cold air is not an issue since all vents and both sides blow ice cold air. Based on this video, there are 5 doors. Recirc, 2 Blend doors, Mode 1 and Mode 2. Can I safely assume the blend doors are the issue here? Winters in Austin, Texas are mild and so I have postponed fixing it for 3 Winters, LOL. I have not taken a single screw out so I am just in the mental troubleshooting phase. TY
It sounds to me like one side of your upper and lower blend doors isn't sealing completely, which would allow some airflow to bypass the heater core. It's impossible to check in the truck unless you have some sort of viewing scope and go backward through the vents.
I have a 2012 2500 with this exact problem. I have no issue with cold air. When full heat, driver side is not as hot and less air flow. I have a single zone system, so my guess is that my first blend door driver side is broken/stuck in the down position? After the air runs through the heater core, are the channels separate through all the modes? Can the dual doors break in the center?
I had a friend help..he is gone..you sanded my life..no ideas where these parts go
Super Great Video.
Thanks for the upload. :)
Can you add a cabin filter to this design?
Where do you recommend I get the foam tape for the vent connecting areas? Awesome video by the way! Your DIY videos are some of the best I’ve seen on the internet.
The best video ever
Is there a way to test all the actuators while the whole thing is out? Would really suck to put everything back together and find out one or more of the actuators are bad.
Hi i did the whole replacement on my 02 1500 the blend doors and the actuators but when i turn the system on i get alot of clicking noise coming from the actuators any advice?
Thank you very much. I will be looking into these things
Hi John,
I have a 2002 Dodge Ram 4.7 I have hot air on passenger side and cold on driver any suggestions I can do without taking the whole system out
Did you figure it out?
Is it possible to get at the defrost actuator without pulling the dash?
I was thumbs up # 1,000! I need to do this to my truck!
Hi, quick question. I have a 2002 4.7L SLT that does not have dual climate control, however, something has happened with the blend door or actuator because only the driver side vents work and not the passenger side. I've been told that even though the truck isn't equipped with dual climate control, it still has the hardware for it. I'm going to take the dash off and get into the HVAC system box (like shown in the video) to see if it's the actuator or the blend door. Does anyone know if I can get to all the screws to separate the black HVAC box without removing it from the truck? I don't want to go through the hassle and expense of evacuating the system and removing the HVAC lines from inside the engine bay. I just want to access the dual climate, blend door and actuator.
John how can I contact you directly? I have an 06 cummins I'm going to rebuild hvac on. Before doing so, I need answers as to why the 2 vents on drivers side blow warm an the 2 vents on passenger blow cold. Quad cab single zone. All ac rebuilt minus hvac box. Help please!!
I'm not 100% clear on one thing. If I just need to replace the doors and not the heater core, do I need to remove the HVAC system from the truck? I am trying to avoid having to drain the AC lines. Anybody have an answer for me? Great video! Thanks!
So in most cases chances are if its a broken door or broken door actuator weather it be a blend door , re-circulation/outside air door , ...etc your having to completely remove the whole unit. This is the equivalent to doing a whole engine overhaul analogy for the hvac car guy. Probably the most difficult part of car ac work is replacing heater cores, evaporators , or doors/door actuators.
Hey where do you put the pag 46 oil for the evaporator core?
IS THERE A WAY TO CHECK OR REPLACE THE MODE #2 ACTUATOR THAT CONTROLS THE FLOOR AND DEFROST WITHOUT TAKING APART THE ENTIRE DASH?
Where ate you located? I'd love for you to fox my truck. Cold on drover hot on passenger and at stops it all blows warm
Thanks Dodge for making shitty blend door actuators 😢😢
and shitty doors.
Foreal bro
Can you buy the whole box new? What would it be called? Thanks
great video and thank you I will be doing mine within the next 2 weeks. You mentioned that the evaporated needs 2 ounce of oil. My question to you is if you know what the rest of the ac system calls for oil measurement in the parts because I will be doing it all ac parts compressor, dryer, expansion, condenser and maybe the fan assembly on a 2007 5.9 Cummins because I don't think mine is working properly only cools when I am on freeway not in town. and as for air out the vents well that sucks as we all know. any help is greatly appreciated
If i dont have heat on my drivers side but i have heat on my passenger side what do you think the problem is?
How do I fit this complete kit with all the doors I need I have an 07 ram 1500
Hello again, is it a big job , removing dash etc or can it be an easy fix ?
Part 1 shows the entire process. It'll take the average person a few hours to get it out. I can have it out in about 45 minutes because I've done it before. Plan for a weekend to get it all taken care of.
All my actuators work correctly at least the 3 I can see. My heater core also works. I am getting no heat throughout the truck. My AC works fine. 2015 Ram 2500 Crew Cab. Any thoughts? I know there is a 4th actuator, but it can only be accessed by removing the dash completely.
Did you flush the system? Take the hoses off near the firewall and flush with a water hose. Both directions. You'll be surprised what comes out.
If the doors are fully intact is it same to assume the issue is with the Actuator motor?
Either the actuator or the control unit is bad.
Is there a total of 5 actuators?
I watched this video in hopes of seeing the direction of airflow and see if that could help me figure out why my passenger side vents dont blow as cold as my drivers side vents. You have any idea what would cause this issue. The air goea straight through the evaporator as soon as the air enters the system but for some reason the passenger side vents arent near as cold as the drivers side vents. 🤔
Evaporator is dirty. Have to clean out the fins.
I got a question. I replaced my blend doors and the 2driver side vents work as they should blowing cold air and hot air, but the 2 passenger side vents don’t blow cold air while I got the ac on. Do you think I placed a blend door incorrectly or did I place the actuator back on incorrectly? My truck is a 06 ram2500 quad cab
Since all the air has to pass through the ac evaporator, why wouldn’t they have used a replaceable cabin air filter in front of that. I’m been working on this on my 08. It’s making me not want to buy another dodge. Hopefully the newer ones have a cabin filter.
That is what I’ll been looking for on my next truck.
Thanks for the video.
I have 2010 ram 5500 but when I turn the ac on only passenger side blows cold. Driver side blows warm. Its not even equipped with 2 zone . Any idea whats going on
Did you have to use any mild adhesive to make the weather stripping stick to air outlets or was it the kind that has the adhesive on it?
It was the peel and stick style. Seems to be holding good so far.
what size was that weather stripping you used? was it 1/2"?
If your lucky the door actuator is easy to access and the door flaps are not the issue. (or maybe a bad electrical connection in an easy accessible area ) Other then that you have to be as good as this guy in pulling off the whole hvac unit underdash.
Are you in Texas
I've replaced all the HVAC doors in my 2006, 2500 dodge diesel, w Manual trans. Heater core, because it was leaking. Replaced the entire A/C system because the compressor was shot. My problem is this. I don't get HOT air out of any vents in any mode. The warmest air I can get is when I set the Temp control knob half way between full hot and full cold and the fan on low.
Watch the blend door drivers while you cycle the system from cold to hot to make sure they're moving all the way.
Did you ever find a fix to this. As mine is now doing the same exact.
Hi, thanks for your info. I am not sure but with my 89 Chevy s10, the Compressor is working and pressures are good. The ac works but when it’s real hot outside 90 plus, the temps coming out is in the 70s. Somehow I think the blend door is broken and it has warm ambient air mixing with the cool air and it doesn’t come out as cool as it should be. Do you have any thoughts on how I can proceed, thank you.
The only way to truly know if you have a broken door without taking the box apart is to reach down the vents with a bore-scope camera. Other things to try is to check to make sure one refrigerant line is cold at the firewall and the other is room temperature. You could also try to stop the coolant flow from the heater core to check to see if it's trying to heat the air inside the box.
Amigo necesito saber donde se les pone el papel metálico que te dan cuando compra la puerta Bendiciones amigo 🙏
Thank you for the video, Detail explain video
wow that's a lot of stuff to take off. I have a 2001 Dodge ram 1500 ext.cab, the AC and heater works, but it only goes out to the upper air against the windshield, do you think I would have to take apart the whole HVAC system like you did?
I'm not sure how a second gen system works because I haven't been into one. Take out the glove box and see if you can visually see the doors moving from the outside. If the stuff on the outside is moving but your airflow does not change, then your doors on the inside are broken.
Quick question. Ive done this before using your videos and when we had the hvac box out we replaced all the actuators. Thinking it would be good to replace everything. When we put the box back in everything was fine for a few weeks then the actuators started clicking for every knob turn except amount of air coming out. Is there a way to test the actuators before i put the box back in? Would it be the big clip that you unhook on the passenger side that comes out with the box?
They can be accessed without pulling the dash but it is extremely difficult to do. Clicking indicates stripped gears, which usually means aftermarket actuators. Only use OEM actuators purchased straight from Dodge. There is a significant difference in quality.
@@flopster843 thank you! I will most likely just pull the box out again since i have no idea which one is bad. But yes these were autozone actuators and i will be putting in oem dodge ones just didnt know if therenwas a way to test them moving the doors before i put the dash back on.
@@katherinerice5415 You can see the drivers with the actuators installed. Put a dot on them with a permanent marker and see if they rotate properly. The clicking one will just shake instead of rotate.
@@flopster843 thank you! I appreciate your help!
Hey, do you remember how many actuators there were in the box. Doing the job now. And want to make sure I get them
4 in a single zone. Only use OEM actuators, the aftermarket ones suck.
I just took apart my dash to get into the hvac system. have a few problems. no heat and smells like anit freeze when I turn AC on. once I took apart the dash I noticed where it's spilling. I was wondering if you know a if they sell a complete kit to replace everything? any recommendations? it's a 2003 dodge ram 1500.
There are no full kits to replace everything. I suggest getting a full door kit Blend Door USA and going to your local parts store and ordering a new evaporator and heater core. This will replace nearly everything in the box while the dash is out.
flopster843 thank you! And do you have a place to send donations?
There's a donate button on CarboniteCummins.com if you feel like it. Thanks!
I have this issue on my 1997 chevy tahoe! I have the feeling I will never have AC again . LOL its stuck on defrost warms the cabin in winter but will not blow cold air out the vent or any air at all. too darn expensive to repair the defective blend doors. I bet it well over $2000
Greetings Sir,
I have a 2005 Dodge Ram 1500 SLT Quad Cab, the only problem I have had for a while, at least it seems, that the A/C doesn't blow to its full potential even when you turn the amount of air released up. On another vehicle, (2003 Hummer H2) the A/C blows hot on the passenger side and only cold on the driver's side. Even when you turn off the air, it seems to still blow a little bit of hot air. If you could please provide some advice, thank for your time and God bless you.
You probably need to clean the evaporator out. Its probably plugged with dirt.
@@flopster843 Thank you sir. Just to make sure, are you referring to the Hummer?
Great video...i did partially..have to go back and do it entirely...thank you very much..
You mentioned adding two ounces of PAG oil to the core. I read the specs and saw that the A/C system called for 7oz of PAG 46 oil in the system. Mind if I ask for a little guidance?
Each component has a portion of that oil inside of it. When you replace the component, you replace the oil that was inside that component. The service manual says to add 2 oz of oil to the evaporator when you change it out to compensate for the 2 oz of oil that's trapped inside it when you removed it. If you change more A/C components, you will add more oil to each respective piece when you put it back together.
Gotcha. That makes sense now. Thanks.
Is there any special procedure to add the PAG oil to the evaporator core? Do you add it to any particular tube or just pour it in? Thanks
I have an 05 ram quad cab. No heat at all on the passenger side, only cool air blows out. What would cause this?
A bad (plugged) heater core or a broken blend door.
Need a video for the Gen 2 Ram 1500's!
Hey mang , ive got heat coming out driver side vents and good flow but less heat and airflow on driver side vents. Cabin filter good , blend door mode and cabin fresh all function properly, no clicking actuators . Help ! Lol cant have chrysler take all my money , 2012 chrysler 200 3.6
Great video! Did you introduce the pag oil 46 through the evap core or through the high pressure line side?
Either way will work. My AC machine has an oil injection system so I usually use that to go through the high side.
flopster843 Thank you!
I just purchased a 2010 Ram 1500. Blows very cold air and very warm heat. but very strong out the defrost vents in all positions in both A/c and Heater... so I know my blend doors are working...correct?
Sounds like you've got a broken mode door. Blend Door USA has a kit to fix the 4th gens as well, I just haven't done a video for it yet.
Are the after market evaporator cores just as good as oem? Thanks for the video . just curious on the after market cause it's way cheaper than the 300 $ dodge one vs 100$. is this a common problem?
I have yet to find any higher quality evaporator cores. Everything is made overseas and is comparable quality wise. I don't feel like you should have to pay a higher price for the same mediocre quality. If you find an American made evaporator, I'd love to hear about it.
Lol I understand that . I was just worried about getting what you pay for saying . I just want to tear it apart one once . it's sad that my 94 c1500 will hang meat and only thing I've ever done is replace compressor cause of the case leaking on the r4 compressor. thanks for the reply ! makes me feel better buying the 100$ core vs the high dollar one
Flopster843 American cooling solutions makes an evaporator in USA. I just got one. How come you did not change the heater core while you were in there?