The other day I heard the typical "Thwup" sound when I switched from Defrost to front vents, but now on High she's really loud like the air is blowing against the dash itself. It will switch between all vents, but it won't switch from outside air to recirculation and it seems it's blowing out at half-speed, but the blower is definitely turning full speed. Temp seems close to accurate considering it was 90+ outside and it's stuck on outside air.

 

Join the club.. I think every 2006 truck on this site has the blend door broken and fixed, including mine. Your description is exactly what mine did as well.

 

yep mine was going out for acouple weeks then on day i got in my truck with the truck running and i shut my door and pop it finnaly broke.

 

If the sound doesn't change between fresh and recirc, you probably have a busted recirc door (BTDT).

One fix is to tear the dash out and take the AC unit apart. Another is to tear the dash out and remove the 'gril' above the fan's intake, reach in and take out the old door (laying across the fan's intake) and work in the new one (BTDT). The third way is to just take the fan motor out (3 screws?) then reach up and take out the old door and put the fan motor back in. That leaves you with no recirc door, but who cares?

 

That's part of the problem, I pretty much keep mine on recirculation when I use the AC, We have a lot of 90-105 summer days.

 

Hasn't been an issue in the FF/Vacaville area. Reach in and pull out the door, drive a week or two without and see what you think. I'm on my 2nd summer without.

 

X2 here! After driving for months with it broken and not knowing what it was, I finally realized it and yanked it out. Not a single problem since. Why replace it when it will just do it again.

 

FF/Vac at least gets a breeze.

I'll try it, but I'm sure I'll take her eventually for it, I despise the incoming air AC.

 

Okay took longer to pull the door out than to find my 5/16 nut driver and remove the screws, but it was pretty close...All of 10 minutes total.

Broken door, upper right area is missing.


Top view of the broken door.


Here is the broken off piece.


There is no way you could install a door through that hole IMO, it's to tight of tolerances even with the one section missing. You can't see or feel where it lines up either.

 

mine did same thing...took to shop and it was repaired under warranty. i hope it does not happen again as it took them all day to get it replaced and fixed.

 

Yup, right you are there. To install a new door, pull the dash out (or roll it upwards), take the recirc motor partially out (try to keep the screws in a bit, easier to tighten it if you don't have to look for the hole), take the air intake grill out with a pair of dikes. This grill is directly behind where your glove box was and is there to keep little dogs out of the fan.

Now, you can reach in there and replace the door and tighten up the door motor (worked on an '03). Harder done than said, but doable. Now the easy part - put your dash back together so it won't squeek.

When you are done, you may need the dealer to do a;

• Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/ CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION).

I didn't do this the first time my door broke and it broke again after 6 months or so. I'm in my 2nd summer without it and don't miss it.

 

So with the door out you are in fresh air mode all the time???

 

Yes, with the door out you're in fresh air mode. So in traffic when your behind another diesel, you end up breathing his exhaust. It sucked for the few days I was without the recirculation mode.

And as it's been noted, your AC effectiveness goes down when you have to constantly cool the hot outside air.