DORMAN 902-326 Hvac Blend Door Repair Kit Installation Guide
- June 1, 2024
- DORMAN
Table of Contents
902-326
INSTALL/REMOVAL INSTRUCTIONS:
BLEND DOOR
902-326 Hvac Blend Door Repair Kit
ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully.
ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully.
902-326
Jeep Cherokee/Wrangler Blend Door Repair Kit
Installation Instructions
Packing list:
– Blend Door
– Axle assembly
– Metal duct tape| Tools required:
– Phillips screw driver
– Rotary tool
– Optional: shop vac, flashlight
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- Locate the actuator motor under the passenger side dash panel above the transmission tunnel. Remove the two Phillips screws that attach the motor to the Heater Box and pull the motor straight down. (See Fig 1.)
ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully. - With the wiring harness still connected to the motor, turn on the HVAC system and verify that the motor turns when you adjust the temperature control. There are three marks on the back of the motor, leave the motor aligned with the middle mark and disconnect the wire.
- Check the fit of the new axle into the motor connection. You can use a small piece of the provided metal tape to shim the fit if it is a little too loose.
- Fig 2. and Fig 3. show the bottom of the heater box and the pattern that will be cut into the bottom of the box.
Fig 2. shows the location of the AC Evaporator core and an internal plastic arc structure that is molded into the inside of the box. When cutting with the Dremel tool, you have to make sure that the blade is pointed straight up when cutting the top of the pattern where the AC core is located. You have plenty of room for the cut, but if you tilted the blade toward the core, it is possible to create damage. The internal structure is just a curved structure that helps divert air through the blend door. Cutting it would not have a serious effect on the operation of the system, but it does make it hard to remove the cut out flap. Neatness doesn’t count since the cutout will be replaced and covered with tape. - Remove the cutout piece and remove the blend door. Sometimes the door breaks completely and can be easily removed. Unless you are very lucky, you will need to make an additional cut to release the door. Fig 4. shows the point to insert the saw bit and cut off the base of the blend door. The diagram below shows how the cut will be done.
- Place the new door into the box. The protrusion on the top of the door axle will fit into the cup at the top of the box and provide the top pivot point for the door. There is a semi-circular retainer that goes up the length of the box you can feel it with your fingers. Slide the door up this guide and it will find the cup. You may have to jiggle it a little, but you’ll know when you get it.
- Pull the bottom of the door out a little and insert the plastic spacer under the door and slide it back in place such that the spacer is between the bottom of the door and the bottom of the box.
- Not required, but it makes it a little easier if you put a small strip of masking tape on the flat portions of the tip of the axle. This will help hold the axle in place when you install the motor. Thread the axle through the bottom hole in the box, through the spacer, and into the axle. The flattened axle will fit into the crimped portion of the axle and provide a strong connection. The axle may be a little loose. This is not a problem. The door will ride on the bottom nylon spacer and the axle is not a support element, just a way to provide torque to the door.
- Place the motor over the axle fitting protruding from the bottom of the box and reattach the motor to the box.
- Connect the wiring back to the motor and verify that the door will move properly when you change the temperature setting. The door fits tightly in the box and there may be slight resistance from the foam sealing rubbing against the box. This is not a problem just make sure that there is no metal to plastic scraping.
- Use the provided metal tape to put the bottom cutout back in place and seal the box. It’s easiest to put a small piece of tape on the inside of the box with the sticky side down and press the plastic cutout up against it and tape around the edges. Depending on your level of concern about the appearance of the repair, you can epoxy the piece back in place and sand and paint the repair. The tape will provide a permanent seal, but there are multiple ways to patch a hole if the tape is not your first choice.
- If you had to make the side cut to extract the axle, be sure to tape over the hole.
- DONE!!! If you have questions or problems, please feel free to contact us through our web site.
Disclaimer:
Even though every attempt is made to ensure this information is complete and
accurate, it is impossible to account for all possible circumstances or
situations. Please consult with a qualified auto technician before attempting
to perform any work you are not qualified to do. Automobiles can be hazardous
to work on; be sure to take all necessary safety precautions. Failure to do so
may result in property damage or personal injury. Certain motor vehicle
standards and performance requirements may apply to our motor vehicle (such as
Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety
Administration). Be sure that your work is performed in accordance with such
standards and that you do not disable any motor vehicle safety feature.
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