Here are some pics of the way I fixed the recirc door on my 2006 Ram
This thing is a pain. *The good news is that the recirc door sub-assembly is accessible by removing the blower motor and the glove compartment. *Here are a few pics of what is involved with a brief description. *Instead of 5+ hours of pulling the dash and replacing the sub assembly I got it fixed for about $2, 20 minutes of my time and I did NOT have to remove the dash.
Here is a pic looking up into the dash with the blower motor removed and broken recirc
door out of the way. *Note the white piece in the enter on the right hand side, this is what is attached to the recirc
door motor - the door sits between this piece and the hole in the housing on the opposite side of the housing. *You will need to remove the glove compartment door and the motor to remove this from the housing. *I used a small pair of vice grips to get hold of it enough to remove it. *
Broken recirc door.
Piece used to replace the broken part of the factory recirc door:
After a bit of bending, customization and trial and error of the above mentioned piece, this is my end result:
The white piece in this picture extends into the recirc sub assembly and the blend door motor inserts into the wide end of this piece. *You need to remove the recirc door motor and pull this out of the recirc door housing to reinstall the door. *When you do this make note of the location of the limiter on the white piece in the pic as it matters when you put it together.
Reassemble by inserting and holding the recirc
door into place with the right hand and inserting the white piece with the left hand, making sure the white piece is fully seated and paying attention to the tab mentioned in first caption. *Reinstall the recirc
door motor again noting tab placement. *(At this point I powered on the HVAC system to make sure it worked as expected. *In my truck the recirc
door moved first followed by the blend door.) *Reinstall blower motor and enjoy a warmer/cooler and quieter driving experience. *