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Home >> Dodge and Ram >> 2003 >> RAM 2500 Van V8-5.2L VIN Y >> Repair and Diagnosis >> Heating and Air Conditioning >> Air Duct >> Service and Repair >> Distribution Duct Replacement
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Distribution Duct Replacement

REMOVAL
The distribution duct can be removed from the vehicle without disconnecting the refrigerant lines or discharging the refrigerant system. The distribution duct assembly must be removed from the vehicle and disassembled for service access of the floor-defrost door or the floor panel door.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Remove the seals from the inlet flange and the panel outlet flange of the distribution duct.
2. Remove the fifteen remaining screws that secure the upper half of the distribution duct to the lower half.
3. Carefully separate the two halves of the distribution duct.

INSTALLATION

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Position the upper half of the distribution duct over the lower half. Be certain that the pivot shafts for both mode doors are in their proper positions.
2. Install fifteen of the screws that secure the upper half of the distribution duct to the lower half, leaving out the screw on the left rear corner of the duct that also secures the vacuum harness retaining strap. Tighten the mounting screws to 2.2 Nm (20 in. lbs.).
3. Install new seals on the inlet flange and the panel outlet flange of the distribution duct as required.
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