Re: Driver Side Blend Door Actuator Removal
I was able to figure this out, so here's how I did it in case someone needs to make the same repair.
Remove all of the lower dash panels under the steering wheel.
Remove the metal plate under the steering wheel
Remove the metal bracket on the right that was holding the plate. A socket extension makes this step much easier.
Remove the lower portion of the heater duct.
You can now visually inspect the blend door actuator up against the center console, attached to the blend box, but the screws will seem impossible to remove!
To get to those screws, you must remove the upper portion of the heater duct. It's made as a clam shell so it comes apart in two pieces. Remove the smaller piece first and then the big one. It's tricky and it took me a while. Don't give up!
You can now access the screws, but you will need a right angle socket driver and T-20 head. I bought one at Home Depot for $20. It's still not easy, but lay on your back under the dash, thread your right arm around the bar in the way, and you'll be able to get them out.
Remove the actuator, replace broken gear, and re-install actuator. I had some trouble lining up the gear, and I was finally able to get it. I had to connect the actuator and turn on the AC so it would move into a better position for the install..
Once it was connected and everything connected I turned on the AC and it calibrated on its own.
I then put the dash back together and never felt such lovely cold air in my life!
Dealer told me I needed a new blend box for $1600! I fixed it myself for a $2 part, and if I had to do it again, it's a 1 to 2 hour job!
All in all this isn't an easy repair ... much harder than the passenger side, but it's doable.