The trouble started about a week ago. Symptoms are as follows;
1. Blended air seems to work fine, hot when I want it hot and cooler when
I move the levers to cooler. (Dual Climate controls)
2. Floor vent seems to work fine, but I thought it used to blow more.
3. Dash vents barely blow at all.
4. Defrost flows nothing.
5. No noticible differance when hitting the recirc button.

All of those above are with the changing of the switch to the correct
position and waiting a bit for the doors to operate.

So, thinks I, lets check the Defrost Door Actuator and the Panel Actuator.
I pull the actuators and measure 150 ohms across the terminals. I manually
move the doors to see they are not stuck. I reconnect the wires but don't
mount the actuators. I pull the plug out of the back of the panel switch and
plug it back in. I reconnect the battery and put the key on. I move the
switch and watch the output shaft driver of the actuators. They don't move
for several second (10-15) then I tried to move one and they both begin
moving on their own. Seems to have been stuck or maybe I didn't wait long
enough?

I replace the actuators on their respective shafts and try the tests as
above. I get the same results (low or no flow of air). You know, I don't
hear the recirc door slamming into position anymore. I can see through the
Recirculation Door Assembly and I can watch the RDA Actuator turn something
inside but my eyes are not as good as they used to be so it takes a min of
back and forth before I realize there is a door missing and something that
looks like a broken plastic shaft.

I fish around with my fingers (a talent refined elsewhere) and feel the door
laying flat blocking the downward flow of air. I moved it up to where I can
see where it broke off the shaft. Crap!

That grill does not seem removable to allow access to the door. The RDA
comes apart with 4(?) screws, two of which I'm thinking are situated so you
must tear the whole truck apart to get to them.

OK, all that for this. Is there any way to pull that busted door out and
place in a new one without pulling the whole dash out (which includes
pulling the steering column)?

 

Recirc door broke.....done close to a dozen of them.

 

So, is there a way to do it without tearing the entire dash out?

 

Steering column is just dropped not pulled.Dash is loosened and a only a few plug ins.Its really not that hard.It can be pulled back on pass.side or taken out.The TSB to replace that broken door pays less then 3 hours I believe.Its a known problem.See if D.C. will offer assistance?

 

Thanks for the advice dog.

I layed the steering wheel to the front seat, took off the glove box, the front panel that goes from the glove box to the center panel, the floor console, etc... took the bolts off both ends of the dash, center to the floor bolts, and the screws and bolts by the windshield, A pillar covers and ends and various stuff.

This allowed me the room to pull the electronic box that sits over the HVAC unit just to the left of the recirc door. Allowing me the room means it was loose enough for me to push up the right side of the dash about 2 inches without removing the dash in its entirity. With that electronic box gone, I had room to take off the recirc actuator. I cut the gril off the air intake (for recirc) and reached in and took out the busted door and the piece that busted off.

I worked out that white nylon bushing thingy (technical term I can't replicate from the manual) and put the new door in (greased). Replaced the thingy and actuator. Tested system. All passed.

Put everything back together. What a pain in the ***. All that for a $30 door ($40 retail). Oh, and I didn't replace the grill I cut out. I figured it was there to keep small cats or dogs out of the HVAC system when on Recirc. Since I keep out the small animals, I thought I might do without the replacement. If someone gives me a good reason to glue it back in, I'll consider it.

This was a major job for me and for major jobs I usually build up some tools. Only thing I needed extra for this was the trim stick. I had a cheap one a long time ago, but I splurged and spent almost $6 on a new one that has a screwdriver type handle. Worked fine.

Again, thanks.

 

I've been thinking about doing mine but I wasn't sure if the HVAC unit needed to come completely out. The service bulletin states to drain the A/C and antifreeeze. It sounds like you did yours without having to do that. Thanks for the info on your repair I'm going to order the door and get to it so my feet dont freeze any longer.

 

I took off my glove box and looked at my recirc door and it is ok so it must be the blend door that broke on mine. It sticks either on defrost or floor but when I put the dial on vent and floor air comes out the vent but not the floor. Does anyone know if I can change out the blend door without removing the whole unit or do I need to drain everything down and take out the whole HVAC box?