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Housing-Air Distribution

WARNING: This page is about a different car, the 2013 Dodge Avenger and 2013 Chrysler 200. 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 blend-air and mode-air doors.

NOTE:

LHD model with A/C shown in illustrations. RHD and heater-only models similar.

Fig 1: HVAC Housing Assembly, Air Distribution Housing & Air Inlet Housing
GC0123390Courtesy of CHRYSLER GROUP, LLC
  1. Remove the HVAC housing assembly and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL .
  2. Remove the air distribution housing (2) from the HVAC housing (1). Refer to HOUSING, HVAC, REMOVAL .
  3. Remove the heater core from the air distribution housing. Refer to CORE, HEATER, REMOVAL .
    Fig 2: Blend Door Actuator & Screws
    GC0123394Courtesy of CHRYSLER GROUP, LLC
  4. Remove the screws (1) that secure the blend door actuator (2) to the left side of the air distribution housing (3) and remove the actuator.
    Fig 3: Blend Door Levers
    GC0123395Courtesy of CHRYSLER GROUP, LLC
  5. Remove the blend door lever (1) from the left side of the air distribution housing (2).
    NOTE:

    To remove the blend door pivot lever, disengage the retaining tab on the lever and pull the lever straight off the pivot shaft.

  6. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4).
    Fig 4: Mode Door Actuator & Bracket
    GC0123396Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    It is not necessary to remove the mode door actuator from the bracket when servicing the air distribution housing.

  7. Remove the three screws (1) that secure the mode door actuator (2) and bracket (3) to the right side of the air distribution housing (4) and remove the actuator and bracket as an assembly.
    Fig 5: Mode Door Cam
    GC0123397Courtesy of CHRYSLER GROUP, LLC
  8. Remove the mode door cam (1) from the right side of the air distribution housing (2).
    Fig 6: Parting Line & Retainers
    GC0082724Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.

  9. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced.
  10. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.
  11. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing.
    Fig 7: Air Distribution Housing & Air Doors
    GC0082725Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If a seal on an air door is deformed or damaged, the air door must be replaced.

  12. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5).
    Fig 8: Mode Door Levers
    GC0082726Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing.

  13. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).
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