I talked to Geno's Garage, and the Tech said his HVAC door is broke also, and won't blow on his feet.

he also said they really don't have time to develop a new product with the holidays upon us.

but i recommended he buy a new door, spec it out, and install it all, and find a way to beef it up, maybe make it out of a softer plastic that won't break, and reinforce it around the pivots and actuating arm.

what kind of interest is there in a piece like this?

my feet are cold in SC, and we are going to VA for Turkey Day, my dash will come apart tonight.


best thread I could find on repairs:
https://www.dieseltruckresource.com/...d.php?t=210483
okay, so maybe not tonight...

it looks like the stops on the Original HVAC housing break off (or do not exist) and they have stronger stops (and new stops) on the upgraded peices from DC.

i am wondering how many people are having the upgraded parts (as shown in the attached PDF) break?

 

When I checked/removed my recirc door, it seemed to me that the motors that move the doors turn way to much. Meaning that the rotor over rotates past the point of contact, breaking the plastic "tabs"off of the door. It would seem that the motors are the problem, and need to have less range.

OR a good old MANUAL actuator!!! Some things just don't need to be electric!! When did we become so weak that we can't open or close a flap??

 

exactly

the problem is that the actuator is moving too far.

I was thinking if we could devise a "spring drive", where the actuator turns a long spring, that has some give.

or maybe a rubber isolator in the drive assembly to keep from snapping the door from the actuator.

something needs to have some give in it.

 

Is this a problem on certain trucks?

Mine has been completely fine, now at 67,000 miles

 

knock on wood. still have my original!- no problems! truck an 04.5 with 90,000 miles!

 

Pull the heater fan and you should be able to get the door through the hole without any further disasembly. Thats how one of the techs on this board says to do it. It is something like a 15 minute repair. My door is still going good at 76k miles.

 

if you were closer, i would make YOU do it...how you been, hoss?

from the looks of it, there are 3 doors in there, and the door i need is over by the steering wheel, from what i gather.

 

Sorry thought that you were talking about the one that sounds like a deck of cards in a bike spoke.

 

There should be a
"never had a problem (so far)"

choice for the poll.
Mine's been fine but I hear it's a problem alright. Dodge should do a recall on them and fix it RIGHT!

 

Still waiting for mine to break.

MikeyB

 

I'd pop for a pernanent fix. Cables would be good if the dash ***** looked/functioned right. I wonder if micro-switches could be added for limits. A slip clutch setup on each actuator might be the easiest. I haven't seen one in person yet but from what I've read I think each one has a short connector between the actuator shaft and the damper socket - maybe a good place for a slip-clutch. Craig