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Housing-Air Distribution

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
NOTE: LHD model shown in illustrations. RHD model similar.
Fig 1: Remove/Install Air Housing-Actuators And Brackets-LH
GC0013962Courtesy of DAIMLERCHRYSLER CORP.
  1. Remove the air distribution housing (1) from the HVAC housing and place it on a workbench (Refer to HOUSING-AIR DISTRIBUTION .
  2. Remove the screws (2) that secure the mode door actuator (4) and the blend door actuator (7) to the driver side of the air distribution housing and remove the actuators.
  3. Remove the screws (5) that secure the blend door actuator mounting bracket (6) and the mode door actuator mounting bracket (3) to the driver side of the air distribution housing and remove the mounting brackets.
    Fig 2: Remove/Install Air Housing-Actuator Linkages-LH
    GC0013963Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove the instrument panel door linkage (3) from the pivot shaft located on the driver side of the air distribution housing (8) and carefully disconnect the linkage rod (2) from the instrument panel door lever (1).
  5. Remove the defrost/demister door linkage (7) from the pivot shaft on the air distribution housing and carefully disconnect the linkage rod (12) from the defrost/demister door lever (11).
  6. Remove the mode door cam (6) from the air distribution housing.
  7. Remove the floor door linkage (5) from the floor door lever (4) and the air distribution housing.
  8. Remove the blend door cam (9) from the blend door lever (10) and the air distribution housing.
    Fig 3: Remove/Install Air Housing-Heater Core
    GC0013964Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove the screw (1) that secures the heater core retaining bracket (2) to the driver side of the air distribution housing (3) and remove the bracket.
  10. Carefully pull the heater core (4) out of the air distribution housing.
    Fig 4: Remove/Install Air Housing-Blend Actuator and Bracket-RH
    GC0013965Courtesy of DAIMLERCHRYSLER CORP.
  11. If equipped with dual zone heating-A/C, remove the screws (1) that secure the blend door actuator (2) to the passenger side of the air distribution housing (3) and remove the actuator.
  12. Remove the screws (4) that secure the blend door actuator mounting bracket (5) to the passenger side of the air distribution housing and remove the mounting bracket.
    Fig 5: Remove/Install Air Housing-Blend Actuator Cam-RH
    GC0013966Courtesy of DAIMLERCHRYSLER CORP.
  13. If equipped with dual zone heating-A/C, remove the blend door cam (1) from blend door lever (2) and the pivot shaft located on the passenger side of the air distribution housing (3).
    Fig 6: Install/Removing Duct-Front Floor Distribution
    GC0013948Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove the six screws (1) that secure the front floor distribution duct (2) to the bottom of the air distribution housing (3) and remove the duct.
    Fig 7: Remove/Install Air Housing-Seal and Screws
    GC0013967Courtesy of DAIMLERCHRYSLER CORP.
  15. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3). If the seal is deformed or damaged, it must be replaced.
  16. Remove the screws (4) that secure the two halves of the air distribution housing together.
    Fig 8: Remove/Install Air Housing-Partition
    GC0013968Courtesy of DAIMLERCHRYSLER CORP.
  17. Carefully separate the left half of the air distribution housing (1) from the right half of the housing (2).
  18. Remove the center partition (3).
    Fig 9: Removing Air Housing-Air Doors
    GC0013969Courtesy of DAIMLERCHRYSLER CORP.
  19. To remove the air doors (1) from the air distribution housing (2), first carefully push down on the tab (3) of the air door lever (4) located in the pivot shaft of the air door being removed.
    NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.
  20. Gently pull the air door lever out of the pivot shaft and remove the air door(s) from the air distribution housing as required.
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