Jeep Grand Cherokee Dual Zone Blend Door RepairMarch 6, 2010 10:43 am Air Conditioning, Consumer, DIY, How To Auto Repair, Jeep
© DenLorsTools.com Summary: Jeep Grand Cherokee’s with dual zone have a common problem of blend doors breaking at the point of actuator engagement. Vehicles affected are 1999, 2000, 2001, 2002, 2003 and 2004 Jeep Grand Cherokees. The automatic temperature control can be affected on the driver or passenger side, making the temp control inoperable. Until recently the refrigerant had to be discharged and the dash removed for repair. Now with a WJ blend door repair kit # K6855685AB, from Mopar/Chrysler/Fiat the repair can be done in the vehicle by even modestly experienced individuals. The kit includes an aluminum door door, a plastic door, a spindle, grease and patch material for resealing the evaporator case after repair. PDF Jeep instructions provided in this car repair article.
NOTE – Since this article was written Jeep has discontinued this repair. We have the alternative kit available which is similar. Our kit makes the doors work together as one eliminating the possibility of ever having to remove the entire case to access the rear actuator. The updated version we sell uses the front, easy to access motor just behind the glove box to control the door. Please verify yours is broken before ordering. See the kit currently for sale at the following link. K6855685AB Alternative. *Please don’t order based on symptoms alone. Please verify this is your problem before ordering.
Tools required for the repair are a Philips screwdriver, a shop vacuum, drill and drill bits, 8″ slip joint pliers, grease pencil or white crayon, grease and wax remover and a small knife. I recommend using a hot knife instead of a drill to cut the case. By using the hot knife, no plastic shavings will fall into the case and there will be less clean up required. Of course using a hot knife requires caution not to damage surrounding wires underneath the dash. If used carefully, it’s much easier to make the required cuts as opposed to using a drill as the Chrysler instructions direct. The repair is done in the area behind the glovebox – so first start by removing the glove box to gain access. After that is removed, unplug the temperature sensor and blend door actuator motor. Keep in mind that the plastic that is cut away WILL be re-used! Take time and outline measurements carefully because the cut-out portion will be put back into place after the repair. The directions are all included on the PDF instructions listed at the bottom of this car repair article. They will also be included with the repair kit when purchased at the dealership.
Here are a couple of additional pictures of the repair area. Notice the plastic 1/2 way inside the case, this is called the inner web and it will NOT be re-installed.
Work will all be done in the vehicle with the glove box removed.
The links below are “how to” instructions which are included with the repair kit purchased from the dealer.
*Footnote 7/29/2012 – We have an alternative to the discontinued K6855685AB.
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