Blend Doors and Evaporator Replacement - Part 2, Rebuild 

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...

Just pulled the hvac box on my 06 ram this weekend. This video made it possible. Thank you sir

GREAT videos, can hardly wait to do this to my 06 over the winter.

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.

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!

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

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 .

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.

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 ...

Nice job explaining this intimidating task! I’ll be doing it soon.

Simply the best how to video out there. Well done sir.

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.

very professional very detailed. I learned a bunch. even tho I don't have a ram. I was searching for durango. great video. thanks

Outstanding video! Thank you!!! Wow!!

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

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

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.

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!!!

Outstanding video. Thank you so much for such a thorough and informative video. Very helpful. Thanks

Best video I've seen on this so far. Most of the others have no lighting. Thanks.

Thank you very much. I will be looking into these things

Super Great Video. Thanks for the upload. :)

This is the BEST video. Very detailed. Step by step. AWESOME 😎. Thanks a lot. I'm sure your video will help to many people. 👏👏👏

8 degrees outside had to drive 320 miles with frozen toes! cant wait to do this repair asap

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.

Excellent videos!

Thanks! Gonna help me a lot tomorrow at work !

Great video...i did partially..have to go back and do it entirely...thank you very much..

Great video. The Dodge HVAC system is a real Turd.

Wow. Wish you were close by... I need that done to my Dodge Ram 1500

Great vid. Time to rig the blend doors to full cold! lol

Thank you for the video, Detail explain video

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.

Well done.

very helpful and great videos working on 03 3500

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.

I was thumbs up # 1,000! I need to do this to my truck!

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

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.

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

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?

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?

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...

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

I had a friend help..he is gone..you sanded my life..no ideas where these parts go

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.

Could a partially clogged heater core cause one side of the truck to have heat and the other not?

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

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?

THANK YOU!

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.

The best video ever

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

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.

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.

Well that's a good day at work.... 😀👊🤘👍

Question? I have a 2004 ram 1500 4.7. The problem I have is no defrost. ] and not to the floor. But I do have a lot of air coming through the front vent for ac. cold air. I can control the fan speed but nothing happens when I turn the knob for heat are the defrost Could the control mod be bad. I will have to pay someone if there is a lot of work to replace doors but if it's just a bad control I can replace it.

Hi i have a 03 Ram and im getting heat on the passenger side,but no heat on the driver side. on all the different settings, would you happen to know which actuator i should checkout to fix this problem? Or could it be something else wrong? Thank you very much..

ALAN BAILEY 12 seconds ago Thank you for the videos, they are fantastic. I really appreciate the Blend door USA rebuild of the 3rd Gen Dodge. I am putting in my new Blend Door USA doors in today. My question is,,, Is there any way to bench test the HVAC unit after door install to make sure everything is OK before I put it back into the truck? Thanks for the input...

Can anyone tell me how to remove the air conditioning and heating box so I can replace the broken blend door actuator on a 2005 Dodge dakota. I can't any videos. Thanks

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.

Need a video for the Gen 2 Ram 1500's!

Thanks for the vid an info.

Thanks Dodge for making shitty blend door actuators 😢😢

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

IS THERE A WAY TO CHECK OR REPLACE THE MODE #2 ACTUATOR THAT CONTROLS THE FLOOR AND DEFROST WITHOUT TAKING APART THE ENTIRE DASH?

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 .

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.

Im just trying to get parts ordered. Are all the actuator motors identical/interchangeable?

We have recently completed the task of replacing all 5 doors inside, a new heater core, a new evaporator, new heater hoses, and a new radiator, I have good heat on the passenger side, but only blows cold air on the drivers side, any suggestions? It's an '03 Dodge Ram 2500 with the 5.7 Hemi.

Wow thank you sir for making this video, best one i have seen so far! I need to replace my evaporator and i wanna replace the heater core and all the doors. Should i replace the actuators also? Anything else you recommend while its apart?

How do I fit this complete kit with all the doors I need I have an 07 ram 1500

Is it possible to get at the defrost actuator without pulling the dash?

If i dont have heat on my drivers side but i have heat on my passenger side what do you think the problem is?

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. 🤔

Bad Ass Video Sir!!!!!

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

Hey where do you put the pag 46 oil for the evaporator core?

Thanks

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?

Question? There are 4 actuators all with different numbers. is there a sequence required to have correct actuator in place? this is a 2003 dodge Ram looks like what your working on in the Video. I disconnect entire wire harness and Actuators. worried about thier location. Any Advice. Pete Damron East Texas

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?

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

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 have a 06 3500 and I'm getting no heat the blower is working aslo the vent selection is working fine i can hear the motors working

Can you buy the whole box new? What would it be called? Thanks

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!!

Is there a total of 5 actuators?

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.

If the doors are fully intact is it same to assume the issue is with the Actuator motor?

Hi there, can you tell me how many blend doors does my Dodge Ram 1500 2003 have ? I want to make sure I have all the right amount of doors before I start the job on my truckBig thanks again

Amigo necesito saber donde se les pone el papel metálico que te dan cuando compra la puerta Bendiciones amigo 🙏

Question for anyone that can answer it. I have a 2006 2500 Diesel Megacab and my heater only seems to get real warm after making a left turn. which door is going to be the fauly one ?

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

I noticed numbers 1 through 4 on the backside of the actuators to when I took them off my hvac box thinking it didn’t mater to where they go back but no I’m worried!!!

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.

Hey, do you remember how many actuators there were in the box. Doing the job now. And want to make sure I get them

Great video! Did you introduce the pag oil 46 through the evap core or through the high pressure line side?

Hello again, is it a big job , removing dash etc or can it be an easy fix ?

After disconnecting actuators, replacing doors and putting it all back together. Will the actuators re-calibrate to the correct positions without breaking the doors?