My first attempt at a "how to" so be kind.
I wanted to submit this because I don't want anyone to make the same mistake I did(I'll get to that).
So recently I noticed that while my temp control was set at 71 for both sides, the passenger side would just blow cold air. I did my research (I will save my rant how this happens with a 45K Jeep 2 years old).
I found the info on the gear and dove in.
1) always disconnect the negative lead to the battery.
2) removing the glove box. Nothing earth shattering hear pinch the sides and disengage the string that slows its opening. If you have changed the cabin filter you know all about that.
3)remove the piece the holds the floor duct and floor light (all push pins)
4) remove the surround that holds the glove box. Here is where I start to get in trouble. In the two upper rubber stops you have 15 Torx bolts...Yeah I didn't know but luckily I didn't yank too hard before I realized I should investigate. So you remove those two screws and the 4 exposed bolts on the bottom (2nd pic)
Also unplug the glove box light and floor light.
5) as soon as you can put a piece of tape (White) over the plastic edge in the pic. That is beyond sharp. I have a ton of cuts on my hands and wrist. You can see the actuator that has the broken gear just beyond the tape.
The actuator has two permanent locating pins and two brass colored screws (15 Torx) I removed the bottom duct work but not the top. I had a screw driver that had a ratchet for the two screws. Not enough room for a long screw driver in there so use something short or angled
This is what it looks like with the actuator removed. That is the gear for the blend door
Actuator removed and unplugged from harness with broken gear attached
You can't put the new gear on wrong because its keyed to go on only one way.
These are the two gears old broken one on the left. Part # 68214880AA was $2 at my dealer.
When you put the actuator back on with the gear on it, make sure it works freely.
I put it on the first time and it was off a tooth and did not.
After I secured the two 15 torx screws I reconnected the battery and started the Jeep just to make sure it worked without binding. It did!
Now put everything back in reverse. don't forget to plug both the floor light and the glove box light back in.
The part where I messed up on was that I thought initially that I had to remove the wood trim above the glove box. You don't but I did nic the wood by the center console. I also have not been able to get the trim around the passenger side vent to sit right. If anyone has some insight please help. All of that could have been avoided if I knew that it did not need removed. All in all pretty easy fix.
I hope it helps someone.