Operation CHARM: Car repair manuals for everyone.
Home >> Dodge and Ram >> 2011 >> Durango 2WD V6-3.6L >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Overhaul >> HVAC Housing - Disassembly >> Front Air Distribution Housing

Front Air Distribution Housing






HOUSING-AIR DISTRIBUTION

Special Tools:






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





1. Remove the air distribution housing (1) from the HVAC housing and place it on a workbench HVAC Housing - Removal.
2. 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.





3. 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.
4. Remove the right side blend door drive gear (4).





5. Using Trim Stick (4) or equivalent, disconnect the mode door drive gear lever arm (2) from the right side floor air door lever (3).
6. Remove the mode door drive gear lever (1) and lever arm from the right side the air distribution housing.





7. 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.





8. Using 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).





9. Remove the console air door lever (1) and the mode door driven gear (2) from the right side the air distribution housing.





10. Using Trim Stick (3) or equivalent, remove the two mode air door levers (1 and 2) from the right side the air distribution housing.





11. Using Trim Stick (2) or equivalent, remove the blend door gear (1) from the right side the air distribution housing (3).





12. 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.






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

13. 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.





14. Remove the evaporator temperature sensor (1) from the right side of the air distribution housing (2).





15. 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.





16. Remove the blend door drive gear (1) from the left side of the air distribution housing (2).
.




17. Using Trim Stick (3) or equivalent, remove the blend door gear (1) from the left side the air distribution housing (3).





18. Using 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).






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

19. 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.






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

20. Carefully cut the foam seal (1) along the parting lines (2).
21. Remove the thirteen screws (3) that secure the two halves of the air distribution housing (4 and 5) together.
22. Carefully remove the left half of the air distribution housing from the right half of the air distribution housing.






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

23. Remove the left side partition (1), blend air door (2) and mode air doors (3).
24. Remove the center partition (4) from the right half of the air distribution housing (5).






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

25. 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).
26. Remove the floor console air door (7) and linkage (6).
27. If required, remove the linkage from the floor console air door.

pro multis · About Operation CHARM