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Home >> Dodge and Ram >> 2015 >> Durango SXT, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 133 (Heating & Air Conditioning (Service Information)) >> Distribution >> Housing, HVAC >> Assembly >> Housing-Air Distribution

Housing-Air Distribution

WARNING: This page is about a different car, the 2016 Dodge Durango. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Right Side Partition, Blend Air Door, Mode Air Doors, Floor Console Air Door & Linkage
GC0145950Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the linkage (6) onto the floor console air door (7).
  2. Install the floor console air door and linkage into the right side of the air distribution housing (3).
  3. Install the right side partition (1), blend air door (2) and mode air doors (4 and 5).
    Fig 2: Left Side Partition, Blend Air Door, Center Partition, Air Distribution Housing & Mode Air Doors
    GC0145949Courtesy of CHRYSLER GROUP, LLC
  4. Align the air door pivot shafts and the right side partition with the holes in the center partition (4) and carefully install the center partition onto the right half of the air distribution housing (5).
  5. Install the left side partition (1), blend air door (2) and mode air doors (3).
    Fig 3: Foam Seal & Parting Lines
    GC0145948Courtesy of CHRYSLER GROUP, LLC
  6. Align the air door pivot shafts and the left side partition with the holes in the left half of the air distribution housing (5) and carefully install the left half of the air distribution housing onto the right half of the air distribution housing (4).
  7. Install the thirteen screws (3) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 N.m (20 in. lbs.).
  8. Inspect the foam seal (1), especially at the parting lines (2). If the foam seal is ok, adhere the cuts made at the parting lines back together with a small amount of RTV sealer. If the foam seal is deformed or damaged, it must be replaced.
    Fig 4: Floor Air Door & Air Distribution Housing
    GC0145947Courtesy of CHRYSLER GROUP, LLC
  9. Install the floor air door (1) into the left side of the air distribution housing (2).
    Fig 5: Floor Air Door Linkage Rod, Floor Air Door Gear, Linkage Rod & Floor Air Door
    GC0145951Courtesy of CHRYSLER GROUP, LLC
  10. Install the floor air door linkage rod (2) and the left side floor air door gear (4). First, align together the largest tooth opening on the gear with largest tooth on the linkage rod (1). Then install the gear into the left side floor air door (3), with the door in the open position as shown. Make sure the gear is fully engaged to the air door.
    Fig 6: Blend Door Gear & Air Distribution Housing
    GC0145952Courtesy of CHRYSLER GROUP, LLC
  11. Align the blend door gear (1) with the blend air door on the left side the air distribution housing (2) and install the gear. Make sure the gear is fully engaged to the air door.
    Fig 7: Blend Door Drive Gear & Air Distribution Housing
    GC0145944Courtesy of CHRYSLER GROUP, LLC
  12. Align the blend door drive gear (1) with the blend door gear on the left side of the air distribution housing (2) and install the drive gear. Make sure the gears are aligned as shown.
    Fig 8: Blend Door Actuator, HVAC Air Distribution Housing, Blend Door Cam & Actuator Output Shaft
    GC0145953Courtesy of CHRYSLER GROUP, LLC
  13. Position the blend door actuator (1) into the vehicle.
  14. Install the blend door actuator onto the driver side of the HVAC air distribution housing (2). If necessary, rotate the actuator slightly to align the flat area of the splines on the actuator output shaft (4) with the flat area in the blend door cam (3).
    Fig 9: Two Screws, Blend Door Actuator & Air Distribution Housing
    GC0145943Courtesy of CHRYSLER GROUP, LLC
  15. Install the two screws (1) that secure the blend door actuator (3) to the left side of the air distribution housing (4). Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 10: Evaporator Temperature Sensor & Air Distribution Housing
    GC0145941Courtesy of CHRYSLER GROUP, LLC
  16. Install the evaporator temperature sensor (1) onto the right side of the air distribution housing (2).
    Fig 11: Floor Air Door & Air Distribution Housing
    GC0145940Courtesy of CHRYSLER GROUP, LLC
  17. Install the floor air door (1) onto the right side of the air distribution housing (2).
    Fig 12: Screw, Door Gear Bracket & Air Distribution Housing
    GC0145939Courtesy of CHRYSLER GROUP, LLC
  18. Position the mode door gear bracket (2) onto the right side of the air distribution housing (1) and install the retaining screw (3). Tighten the screw to 2 N.m (17 in. lbs.).
    Fig 13: Blend Door Gear & Air Distribution Housing
    GC0145955Courtesy of CHRYSLER GROUP, LLC
  19. Align the blend door gear (1) with the blend air door on the right side the air distribution housing (2) and install the gear. Make sure the gear is fully engaged to the air door.
    Fig 14: Two Mode Air Door Levers & Air Distribution Housing
    GC0145956Courtesy of CHRYSLER GROUP, LLC

    Align the two mode air door levers (1 and 2) with the mode air doors on the right side the air distribution housing (3) and install the levers. Make sure the levers are fully engaged to the air doors.

    Fig 15: Console Air Door Lever & Mode Door Driven Gear
    GC0145936Courtesy of CHRYSLER GROUP, LLC
  20. Align the previously installed mode air door lever to the slot in the back of mode door driven gear (2) and install the driven gear.
  21. Align the console air door lever (1) to console air door linkage rod and the slot in the front of the mode door driven gear and install the lever. Make sure the lever is fully engaged to the linkage rod and the driven gear.
    Fig 16: Floor Air Door Linkage Rod, Lever Assembly, Linkage Rod & Right Side Floor Air Door
    GC0145957Courtesy of CHRYSLER GROUP, LLC
  22. Install the floor air door linkage rod (1) and the right side floor air door gear and lever assembly (2). First, align together the largest tooth opening on the gear and lever assembly with largest tooth on the linkage rod (3). Then install the gear and lever assembly into the right side floor air door (4), with the door in the open position as shown. Make sure the gear and lever assembly is fully engaged to the air door and that both floor air doors open and close together simultaneously.
    Fig 17: Mode Door Drive Gear & Aligned Position
    GC0145934Courtesy of CHRYSLER GROUP, LLC
  23. Align the mode door driven gear (1) to the mode door drive gear (2) in the position shown (3).
  24. Align the previously installed mode air door lever to the slot in the back of mode door drive gear and install the drive gear.
    Fig 18: Mode Door Drive Gear Lever, Mode Door Drive Gear, Door Drive Gear Lever Arm & Right Side Floor Air Door Lever
    GC0145958Courtesy of CHRYSLER GROUP, LLC
  25. Align the tab on the back side of the mode door drive gear lever (2) with the slot on the front of the mode door drive gear (1) and install the lever.
  26. Connect the mode door drive gear lever arm (4) to the right side floor air door lever (3).
  27. Rotate the mode door drive gear back and forth by hand. Make sure that the mode air doors at the top of the housing, and the floor air doors on each side of the housing, open and close fully, with no binding or excessive effort required.
    Fig 19: Three Screws, Actuator Bracket & Distribution Housing
    GC0145932Courtesy of CHRYSLER GROUP, LLC
  28. Position the mode door actuator bracket (2) to the right side of the air distribution housing (3) and install the three retaining screws (1). Tighten the screws to 2 N.m (17 in. lbs.).
  29. Align the blend door drive gear (4) with the blend door gear and install the drive gear. Make sure the gears are aligned as shown.
    Fig 20: Blend Door Actuator, Air Distribution Housing, Actuator Output Shaft & Blend Door Drive Gear
    GC0145903Courtesy of CHRYSLER GROUP, LLC
  30. Install the blend door actuator (1) onto the right side of the air distribution housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (2) with those on the blend door drive gear (3).
    Fig 21: Mode Door Actuator, Mode Door Linkage Bracket, Actuator Output Shaft & Mode Door Drive Gear
    GC0145905Courtesy of CHRYSLER GROUP, LLC
  31. Install the mode door actuator (3) onto the mode door actuator bracket (1). If necessary, rotate the actuator slightly to align the flat area of the splines on the actuator output shaft (4) with the flat area in the mode door drive gear (2).
    Fig 22: Air Distribution Housing, Five Screws, Mode Door Actuator & Blend Door Actuator
    GC0145931Courtesy of CHRYSLER GROUP, LLC
  32. install the five screws (3) that secure the mode door actuator (2) and the blend door actuator (4) to the right side of the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  33. On models equipped with the 3.0L diesel engine, install the electric Positive Temperature Coefficient (PTC) heater. Refer to UNIT, HEATER, INSTALLATION .
  34. Install the air distribution housing onto the HVAC housing. Refer to HOUSING, HVAC, INSTALLATION .
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