Drivers side blend door actuator gear guide.
I just completed this job myself. I replaced the actuator gear on the drivers side. Total time 1:35 minutes.
If you have no heat or AC on one side of the vehicle this is most likely your problem.
Here is the part number for the gear: 68214880AA
Please note. The new gear looks slightly different than the old gear but it is the correct part.
STEP ONE:You need to remove the silencer panel by your knees. Disconnect the hood release and unplug the switch for the lights and gas cap. (6 7MM bolts total )
STEP TWO: Underneath that panel there is a metal plate with four 8MM bolts . Remove those and take off the plate, Remove the bracket that the plate mounts to on the right side (4 bolts, two 8mm two 7mm) The left side can stay.
STEP THREE : Remove lower air duct. There will be a plastic fastener holding it in place. Remove it. It will be no good after you remove it. Replace with zip tie.
STEP FOUR: Make your own tool. You will need a 1/4 wrench and t15 torx. Cut the t15 torx bit in half with a angle grinder. JB weld it or tape it to the wrench. It will save you so much time. I attached a picture below.
STEP FIVE: Completely remove the lower t15 screw on the blend door actuator with your new tool. Simple!
STEP SIX: Remove the upper difficult screw on the blend door actuator. This is the screw everybody struggles with and you absolutely need this homemade wrench for the job. Its very difficult to get back in. I will tell you a secret. YOU DO NOT NEED TO REMOVE THIS SCREW COMPLETELY OR UNPLUG THE ELECTRICAL CONNECTION TO THE ACTUATOR. Remove it 75% of the way and pull out on the blend door actuator. you will have lots of room to replace the gear.
STEP SEVEN: Replace the gear. Mark with a black sharpie the exact position the old gear was in before you take it off. Draw a line from the old gear to the actuator. When you install the new gear just line it up with the mark you have on the actuator.
STEP EIGHT. Test your work before you install those difficult screws. Hold the actuator in place with your hand and see if its operator correctly by using Heat and AC.
STEP NINE: Replace the F@$%ING screws.
STEP TEN: Grab a beer and give yourself a pat on the back! You just saved a ton of money.
STEP ELEVEN: Put it all back together!