Originally Posted by JohnnyV
Jeeples, are you saying fixes like the treater heater are not the way to go?
I think the all aluminum doors are a nice quality part, however I think it's a little overkill as the doors only break after the drive connector stop tabs break. I also think that the aluminum doors can be overpriced.
When I replaced my doors, I decided beforehand that I was just going to replace all of them, even though my AZC codes were for the recirc door only. Pricing out the kits (that kept full AZC function) available it was going to cost me ~$150 for all three doors. Given that I was also buying a new heater core and had some A/C parts that needed to be replaced, I was having a hard time justifying $300-$400 in HVAC parts for a WJ that I purchased for $900.
That being said, someone had replaced the blend doors in my WJ at some point, as they were replaced with the Mopar Upgrade kit, which includes the upgraded drive connector stop tabs (4MM thick vs. 3MM) and new blend doors. The driver's blend door is plastic like OE, but the passenger side blend door is aluminum. The weird thing was that they only replaced one drive connector, the passenger side was the older design with the thinner stop tab. Coincidentally that is the drive connector that can only be accessed by fully removing the HVAC sub-assembly, as it sits right up against the firewall.
For me, I opted to save a few bucks and try one of the little used blend door repair kits available. Also, I have two other vehicles at my disposal, so should I have a blend door failure in the future, I can afford to park my WJ and make repairs at my leisure. If it were my only vehicle, I may have opted for the more 'bombproof' all aluminum doors and drive connectors.