No heat on passenger side - blend door gears - JeepForum.com
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post #1 of 37 Old 08-28-2015, 01:05 PM Thread Starter
IlanLCD
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No heat on passenger side - blend door gears

As our WKs get older, plastic parts are starting to fall apart.

It seems that it is a common issue with the heat at passenger side, there is a plastic part that breaks, that part connects the blend door to the actuator (a lever).

The part can be seen here, at the left the broken part, to the right a good part.

20150828_152153.jpg

If you go to the dealer with such an issue, you will be told that they will inspect, when they find the broken lever, the service manual states that the lever is not serviceable and a new air box is required, part 68020231AA, the part is $200, but to install the part you need to take the dashboard apart ($1,000)

A simple fix is to replace the lever, as it comes out easily, but you will not be able to find one! If you do have the patience you can probably salvage a part at a junk yard, but you will have to do it yourself.

If you are lucky and get the lever then:
1. Remove the glove box.
2. Remove the White receiver to the left of the opening (clips)
3. Remove the actuator (2 hex screws)
4. Replace the lever
5. Assemble is a reverse order

Tops 30 minutes work

Probably such a part can be printed in a 3D printer, i'm checking possibilities.


2008 WK, limited, QTII OX locker, 4.7 super chipped, free flow muffler, K&N filter, modified lift
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post #2 of 37 Old 08-28-2015, 02:28 PM
sfjacks1
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Unless as in my situation it breaks the Blendoor arm then you're just screwed.. Lol
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post #3 of 37 Old 08-29-2015, 02:01 AM Thread Starter
IlanLCD
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If the arm is broken you will have to replace the air box :-(

2008 WK, limited, QTII OX locker, 4.7 super chipped, free flow muffler, K&N filter, modified lift
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post #4 of 37 Old 08-29-2015, 12:06 PM
sfjacks1
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I will Mickey Mouse something for the winter time coming up and do it in the spring
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post #5 of 37 Old 08-29-2015, 12:07 PM
sfjacks1
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The code stored and it says right side Blend over travel, just hoping it's not the heater control head as well
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post #6 of 37 Old 08-29-2015, 12:45 PM Thread Starter
IlanLCD
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Indeed that's the code I had from the Starscan. The actuator travels more than should as the lever is broken.
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post #7 of 37 Old 08-29-2015, 03:32 PM
sfjacks1
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Makes sense...
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post #8 of 37 Old 09-21-2015, 03:48 PM
Bigdlensch
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This is different than the gear isn't it, haven't tore into the jeep yet, my son put change in the vent and I heard it break this morning and then nothing but cold on the passenger side. I can find gears all day long.

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post #9 of 37 Old 10-07-2015, 08:12 PM
Westy
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I've got the no-heat on passenger side problem. I had auto zone check for codes today but none showed up. Might that mean that I have a different issue than the blend door or actuator lever? I'm going to have a look behind the glove box this weekend.
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post #10 of 37 Old 10-10-2015, 03:26 PM
DonTonn
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I've been trying to figure out a no-heat-passenger-side problem for quite a while. Finally found relevant answers on this forum.

Found the broken recirc gear behind the glove box & replaced it with the replacement part (that you'd never be able to find without this forum), but that didn't fix the no-hot-air problem.

Took off the actuator on left side of glove box and found the same broken plastic link shown in the OP of this thread. Has no one found a purchasable replacement for this part?

The design is actually not bad - make the weakest link an easily replaceable cheap plastic part. But WHYYYY couldn't they just assign it a part number and make it available through MOPAR???
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post #11 of 37 Old 10-11-2015, 10:04 AM Thread Starter
IlanLCD
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Quote:
Originally Posted by DonTonn View Post
The design is actually not bad - make the weakest link an easily replaceable cheap plastic part. But WHYYYY couldn't they just assign it a part number and make it available through MOPAR???
Don, glad I helped you.

I can check the cost of producing such a part with a 3D printer. I think your best chance will be to salvage one. We better start picking them.

2008 WK, limited, QTII OX locker, 4.7 super chipped, free flow muffler, K&N filter, modified lift
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post #12 of 37 Old 10-11-2015, 09:05 PM
DonTonn
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Quote:
Originally Posted by IlanLCD View Post
I can check the cost of producing such a part with a 3D printer. I think your best chance will be to salvage one. We better start picking them.
I've had others suggest trying to 3D-print one. Unfortunately, I don't have a whole part to duplicate. My broken piece looked identical to yours, but I couldn't find the broken-off piece.

Looks like I'll be headed to the junkyards this week.
At least it's an easy pull.
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post #13 of 37 Old 10-17-2015, 01:20 PM
Bigdlensch
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Quote:
Originally Posted by DonTonn View Post
I've been trying to figure out a no-heat-passenger-side problem for quite a while. Finally found relevant answers on this forum.

Found the broken recirc gear behind the glove box & replaced it with the replacement part (that you'd never be able to find without this forum), but that didn't fix the no-hot-air problem.

Took off the actuator on left side of glove box and found the same broken plastic link shown in the OP of this thread. Has no one found a purchasable replacement for this part?

The design is actually not bad - make the weakest link an easily replaceable cheap plastic part. But WHYYYY couldn't they just assign it a part number and make it available through MOPAR???
I agree, same piece broken and cannot find it anywhere. Plus there are no pick and pulls around me. Booo

Super slowmo build, 2006 grand cherokee limited 4.7, flowmaster 40, k&n cai, superchips, shorty antennae, 08 Jk Sahara takeoffs w/stock duelers
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post #14 of 37 Old 01-30-2016, 12:38 PM Thread Starter
IlanLCD
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All that having the issue due to the broken part, I have the part printed by a 3D printer, PM me and we can arrange shipment:


part-wk-ac.jpg

2008 WK, limited, QTII OX locker, 4.7 super chipped, free flow muffler, K&N filter, modified lift
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post #15 of 37 Old 01-30-2016, 01:49 PM
JackB1
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This is a thread I saved but gear looks like different part. Just in case it helps go here. http://www.jeepsunlimited.com/forums...ve-box-in-dash
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