Jeep Grand Cherokee Dual Zone Blend Door Repair

10:43 am Air Conditioning, Consumer, DIY, How To Auto Repair, Jeep


©  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.

Jeep_Grand_Cherokee_HVAC_Repair 2

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.

Blend Door Repair PDF Page One

Blend Door Repair PDF Page Two

Blend Door Repair PDF Page Three

Blend Door Repair PDF Page Four

Blend Door Repair PDF Page Five

Blend Door Repair PDF Page Six

Blend Door Repair PDF Page Seven

Blend Door Repair PDF Page Eight

*Footnote 7/29/2012 – We have an alternative to the discontinued K6855685AB.

Related Jeep Repair Article

Jeep Grand Cherokee Blend Door for sale

107 Responses
  1. NewDIYer :

    Date: January 11, 2016 @ 12:28 pm

    Firstly, thanks to dennisb.

    I bought a used 2000 JGC Limited in the summer. Recent needs for heat made me aware of issues.

    After driving a little bit (15 minutes maybe), an antifreeze odor came out with use of the heat. If I turned on the heat right after starting the Jeep, no antifreeze smell. Almost like there was no time for it to build up.

    Today was our first 0° day. I started the Jeep and warmed it for no more than 5 minutes, then set on my way. Once the temp gauge read about 200, I turned on the windshield defrost vents and got cool air. I switched to the front vents and the driver side gave me heat, while the passenger side was cold.

    Is it possible that the kit will handle both issues? Or is the antifreeze smell issue its own animal?

  2. dennisb - Auto Tool Sales :

    Date: January 11, 2016 @ 12:34 pm

    Antifreeze odor indicates the heater core is leaking or at least starting to seep. The blend door has nothing to do with the smell. Only the driver zone and passenger zone temps if the door is broken. Good Luck.

  3. NewDIYer :

    Date: January 11, 2016 @ 12:48 pm

    Okay, so it may be just seeping, because there didn’t seem to be any coolant loss.

    Heater core replacement sounds like a non-DIY job, so maybe I should have that taken care of, then see about this blend door thing afterword.

    Thanks dennisb.

  4. dennisb - Auto Tool Sales :

    Date: January 11, 2016 @ 12:54 pm

    When the case is out, that would be the best time to replace any doors or actuators that are bad.

  5. NewDIYer :

    Date: January 11, 2016 @ 1:11 pm

    Yeah, I figured that would be the logical way to do it, but I was weighing that against the cost of the dealer doing the heater core AND the blend door stuff.

    Probably need a second mortgage.

    Thanks so much for your help, and speed of reply.

  6. Phil :

    Date: March 13, 2016 @ 7:48 pm

    Is the blend door repairable from behind the glove box on a 2008 Jeep Grand Cherokee with the Overland Package?
    Thank you…

  7. dennisb - Auto Tool Sales :

    Date: March 16, 2016 @ 3:24 pm

    We don’t have anything for the newer models at this time. Sorry.

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