I knew it was only a matter of time so I printed scbroders' excellent thread on the broken damper a while back. I've been keeping mine on "max" since it got hot around here and rarely needed high fan but Fri. the A/C wasn't keeping up and I noticed the airflow was decreasing so I turned it to high and heard a loud shuddering in the evap area and I turned it back down a notch. I also heard loose parts rattling in there when I got on a washboard road. I was afraid to try different damper positions (floor/dash) for fear of it quitting completely. We made it thru our camping trip and when we got close to home the flow came up and cooling was good again so the broken damper must have gotten itself back into place again. I'm going to try to get by til cooler weather and maybe shut off the heater water to see if that helps. Scbroder listed these parts:
5127758AA lower HVAC housing $43
5073964AA defrost door $19
5019632AA coupling $7
68004226AB recirc housing w/door and actuator $20
Does anyone know if this is all the possible parts needed besides the stuff to recharge the AC? I only have my truck and I'm a long way from a dealer so I'd like to have all the parts that are known to break before I start. TIA! Craig

 

per iatn there is a update for the HVAC in the DBR III under misc. it is not in print, and will only be found in the dbr III. needs to be done to solve this from happening. was told that most techs do not know of it. I just put everything new under dash and made an apointment to reprogram then told there was no update for a 03. looked on iatn and found post telling of update not a reprogam.

 

Tried to find it but apparently I am too stupid. Is that how he spells his name?

 

It's way too old to come up in a search now. I printed it a long time ago before it became outdated. The title is "HVAC Removal with Pictures" and the author is scbroder and it's dated 9-4-06. It's awesome - he posted pics of all the steps and showed where all the bolts and screws are located to take the dash and AC box apart. I hope to find a savvy parts person who will know all the right pieces/parts to sell. I wonder if a moderator has a way to dig it up and post it again. Craig

 

This one was done by ratiratl (on page two). Same thing or different? https://www.dieseltruckresource.com/...tch+1%2F4+turn

 

From what you are describing, you could have only lost the fresh/recirc door. You can visually verify whether that one is the problem by just removing the glove box.

 

Bark, the thread I have is totally different. It starts with removing the AC accumulator and then the inside stuff. I kept it on max last weekend and was afraid to try anything else in fear of losing all the cooling. This weekend I will try all the modes and see if I can figure out which part has the problem. Thanks for the help and that other thread. That looks like a good one, too. Craig

 

Lots of luck and I hope its not too hot for you to work on it.

 

Well, the recirc door coupler is broken for sure - a piece of it was in the blower wheel so I taped the door to the recirc position for now. I also have a problem with the blend door - air will only come out the dash but that works for me year-round, where I'm at. That ratlratl thread is just as good as the one I printed - actually better cuz of the shortcuts. Did ratlratl ever do the writeup on the blend door? Sounds like the whole heater box has to be replaced. I'm not going to mess with mine til I know more about that. Craig

 

Feel free to take a look at this thread. https://www.dieseltruckresource.com/...d.php?t=210483

I've got a link in it to another thread that shows a pdf of the scbroders instructions as well as disassembly pics of the actual HVAC box. Jeff

 

Jeff 032500 WI: Thanks. I dont know how I missed that thread!!! Its excellent.