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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 >> Disassembly >> 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.
NOTE:

The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

Fig 1: Air Distribution Housing, Five Screws, Mode Door Actuator & Blend Door Actuator
GC0145931Courtesy of CHRYSLER GROUP, LLC
  1. Remove the air distribution housing (1) from the HVAC housing and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL .
  2. On models equipped with the 3.0L diesel engine, remove the electric Positive Temperature Coefficient (PTC) heater from the air distribution housing. Refer to UNIT, HEATER, REMOVAL .
  3. Remove 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 and remove the actuators.
    Fig 2: Three Screws, Actuator Bracket & Distribution Housing
    GC0145932Courtesy of CHRYSLER GROUP, LLC
  4. Remove the three screws (1) that secure the mode door actuator bracket (2) to the right side of the air distribution housing (3) and remove the bracket.
  5. Remove the right side blend door drive gear (4).
    Fig 3: Trim Stick, Mode Door Drive Gear Lever Arm & Air Door Lever
    GC0145933Courtesy of CHRYSLER GROUP, LLC
  6. Using Trim Stick (special tool #C-4755, Trim Stick) (4) or equivalent, disconnect the mode door drive gear lever arm (2) from the right side floor air door lever (3).
  7. Remove the mode door drive gear lever (1) and lever arm from the right side the air distribution housing.
    Fig 4: Mode Door Drive Gear & Aligned Position
    GC0145934Courtesy of CHRYSLER GROUP, LLC
  8. Remove the mode door drive gear (1) from the right side of the air distribution housing. Note the proper aligned position (3) of the drive gear to the driven gear (1) for reassembly.
    Fig 5: Trim Stick, Gear Assembly, Door Linkage Rod & Floor Air Door
    GC0145935Courtesy of CHRYSLER GROUP, LLC
  9. Using Trim Stick (special tool #C-4755, Trim Stick) (3) or equivalent, remove the right side floor air door lever and gear assembly (1) and the floor air door linkage rod (2) from the right side floor air door (4).
    Fig 6: Console Air Door Lever & Mode Door Driven Gear
    GC0145936Courtesy of CHRYSLER GROUP, LLC
  10. Remove the console air door lever (1) and the mode door driven gear (2) from the right side the air distribution housing.
    Fig 7: Trim Stick & Two Mode Air Door Levers
    GC0145937Courtesy of CHRYSLER GROUP, LLC
  11. Using Trim Stick (special tool #C-4755, Trim Stick) (3) or equivalent, remove the two mode air door levers (1 and 2) from the right side the air distribution housing.
    Fig 8: Trim Stick & Blend Door Gear
    GC0145938Courtesy of CHRYSLER GROUP, LLC
  12. Using Trim Stick (special tool #C-4755, Trim Stick) (2) or equivalent, remove the blend door gear (1) from the right side the air distribution housing (3).
    Fig 9: Screw, Door Gear Bracket & Air Distribution Housing
    GC0145939Courtesy of CHRYSLER GROUP, LLC
  13. Remove the screw (2) that secures the mode door gear bracket (2) to the right side of the air distribution housing (1) and remove the bracket.
    Fig 10: Floor Air Door & Air Distribution Housing
    GC0145940Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  14. Remove the floor air door (1) from the right side of the air distribution housing (2) by carefully lifting the front of the air door out of the housing, then slide the air door forward to disengage the door pivot shaft from the housing.
    Fig 11: Evaporator Temperature Sensor & Air Distribution Housing
    GC0145941Courtesy of CHRYSLER GROUP, LLC
  15. Remove the evaporator temperature sensor (1) from the right side of the air distribution housing (2).
    Fig 12: Two Screws, Blend Door Actuator & Air Distribution Housing
    GC0145943Courtesy of CHRYSLER GROUP, LLC
  16. Remove the two screws (1) that secure the blend door actuator (2) to the left side of the air distribution housing (3) and remove the actuator.
    Fig 13: Blend Door Drive Gear & Air Distribution Housing
    GC0145944Courtesy of CHRYSLER GROUP, LLC
  17. Remove the blend door drive gear (1) from the left side of the air distribution housing (2).
    Fig 14: Trim Stick & Blend Door Gear
    GC0145945Courtesy of CHRYSLER GROUP, LLC
  18. Using Trim Stick (special tool #C-4755, Trim Stick) (3) or equivalent, remove the blend door gear (1) from the left side the air distribution housing (3).
    Fig 15: Trim Stick, Air Door Gear, Linkage Rod & Left Side Floor Air Door
    GC0145946Courtesy of CHRYSLER GROUP, LLC
  19. Using Trim Stick (special tool #C-4755, Trim Stick) (3) or equivalent, remove the left side floor air door gear (4) and the floor air door linkage rod (1) from the left side floor air door (2).
    Fig 16: Floor Air Door & Air Distribution Housing
    GC0145947Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  20. Remove the floor air door (1) from the left side of the air distribution housing (2) by carefully lifting the front of the air door out of the housing, then slide the air door forward to disengage the door pivot shaft from the housing.
    Fig 17: Foam Seal & Parting Lines
    GC0145948Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the foam seal is deformed or damaged, the seal must be replaced.

  21. Carefully cut the foam seal (1) along the parting lines (2).
  22. Remove the thirteen screws (3) that secure the two halves of the air distribution housing (4 and 5) together.
  23. Carefully remove the left half of the air distribution housing from the right half of the air distribution housing.
    Fig 18: Left Side Partition, Blend Air Door, Center Partition, Air Distribution Housing & Mode Air Doors
    GC0145949Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the rubber seal on any air door is deformed or damaged, the air door must be replaced.

  24. Remove the left side partition (1), blend air door (2) and mode air doors (3).
  25. Remove the center partition (4) from the right half of the air distribution housing (5).
    Fig 19: Right Side Partition, Blend Air Door, Mode Air Doors, Floor Console Air Door & Linkage
    GC0145950Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the rubber seal on any air door is deformed or damaged, the air door must be replaced.

  26. Remove the right side partition (1), blend air door (2) and the mode air doors (4 and 5) from the right side of the air distribution housing (3).
  27. Remove the floor console air door (7) and linkage (6).
  28. If required, remove the linkage from the floor console air door.
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