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Air Distribution Housing

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. 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: Actuators and Brackets-LH-R and I
GC0028339Courtesy of DAIMLERCHRYSLER CORP.
  1. Remove the air distribution housing (1) from the HVAC housing and place it on a workbench (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - AIR DISTRIBUTION HOUSING - REMOVAL) .
  2. Remove the screws (2) that secure the blend door actuator (4) and the mode door actuator (7) to the driver side of the air distribution housing and remove the actuators.
  3. Remove the screws (3 and 6) that secure the blend door actuator mounting bracket (5) and the mode door actuator mounting bracket (8) to the driver side of the air distribution housing and remove the mounting brackets.
    Fig 2: Door Linkage-LH-R and I
    GC0028340Courtesy of DAIMLERCHRYSLER CORP.
  4. Using a flat bladed tool, remove the upper defrost/panel door pivot gear (1), front floor door pivot gear (4) and the blend door stop (5) from the driver side of the air distribution housing (3).
  5. Remove the upper defrost/panel door linkage rod (8) and the mode door cam (7) from the air distribution housing.
  6. Remove the lower defrost/panel door pivot gear (2) and the front floor door linkage rod (6) from the air distribution housing.
    Fig 3: Actuators and Bracket-RH
    GC0028341Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the screws (1) that secure the rear floor/console door actuator (2) to the passenger side of the air distribution housing (3) and remove the actuator.
  8. If equipped with dual zone heating-A/C, remove the screws (6) that secure the blend door actuator (7) to the passenger side of the air distribution housing and remove the actuator.
  9. If equipped with dual zone heating-A/C, 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 4: Heater Core and Stop-R and I
    GC0028342Courtesy of DAIMLERCHRYSLER CORP.
  10. If equipped with dual zone heating-A/C, remove the blend door stop (1) from the passenger side of the air distribution housing (2).
  11. Carefully pull the heater core (3) out of the passenger side of the air distribution housing.
    Fig 5: Housing Retainers-R and I
    GC0028343Courtesy of DAIMLERCHRYSLER CORP.
  12. 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.
  13. Remove the 4 metal clips (4) that secure the two halves of the air distribution housing together.
  14. Remove the eight screws (5) that secure the two halves of the air distribution housing together.
    Fig 6: Housing-Seperate
    GC0028344Courtesy of DAIMLERCHRYSLER CORP.
  15. Carefully separate the left half of the air distribution housing (1) from the right half of the air distribution housing (2).
  16. Remove the center partition (3) from the distribution housing.
    Fig 7: Center Partition
    GC0028345Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
  17. If required, remove the front floor air doors (1 and 3) from the center partition (2) by disengaging the retaining tabs (4) and pulling the air doors apart from each other.
    Fig 8: Passenger Side Air Doors
    GC0028346Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
  18. Remove the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3), rear outlet-air door (4) and the blend-air door (5) from the passenger side air distribution housing (6) as required.
    Fig 9: Driver Side Air Doors
    GC0028347Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
  19. Remove the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3) and the blend-air door (4) from the driver side air distribution housing (5) as required.
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