Yep, I certainly have experienced this before. I had thought it was the blend doors or something binding a little and then slapping into position.

I've noticed it over the last 50,000 miles or so, and the system still works as it is supposed to (apart from the noise, of course!). So, I wouldn't say it is a sign of impending failure...but I wouldn't be surprised if at some point down the road I'll be under the dash looking into this more!

 

Damn, well think I will go in, even if the dealer sends me back out the door with a "no fault found". I'm just about out of warranty so want to get stuff looked at.

 

Yes, go in!! My 99 made the same noise and ended up the little tab on the door broke off, thus giving me the "RECIRC DOOR TRAVEL TOO FAR"

 

yup, I went in and they have to order some part, then they need my jeep for at least a full day to tear the dash apart!

it's under warranty so no cost to me.

 

Can you find out that part name?

 

I had mine replaced over a year ago...mine was not closing properly and spit out heat with it off. Does anyone's make noises when u switch output settings like straight and footwells to windshield or any switch?

 

Mine does as well. That's why I'm curious to know the part name.

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quick update, new part doesn't arrive till end of the month, some sort of backorder, I will post the info on the repair once it is done.

 

ok, so the repair is finally done, yes it a month to get the parts in.

repair done under warranty, but the service writer told me it would've been $1800 for the repair without warranty.

Mopar Part 68020402AB DISTRIBUTION HOUSING retail price $305
Mopar 68072190AA A/C AND HEATER ACTUATOR retail price $14

the killer is labor, it was 8 hours to tear the dash a part, and the air conditioning had to be drained and refilled.

 

For those of you who have this issue in the future pull out the glove box (no screws at all to remove) and check the little AC/ and Heater actuator gear to see if it's broken. With the glove box removed it is the motor straight ahead and slightly to the right with a one inch electrical connector coming out of it. There are only three torx screws to remove along with the electrical connector. Most likely it is the old design which is prone to breaking. It mates with a gear on the recirculation flap and it can't travel too far because the door is larger than the opening. $16 at the dealership for the part (68072190AA), no dash removal, and no air conditioning drain and refill. That is the biggest bunch of BS I have ever heard. The gear just slides on and off. It took me about 20 minutes to replace the part.

Here's a photo of the old part vs. the redesigned part(right). They have filled in the area that used to be hollow to prevent it from breaking at either end which was its weakest point. I hope this helps.

 

I am a bit puzzled with the actuator motor. I've bought a new enforced actuator ( like the one shown above) but yesterday when i was trying to replace the broken part i've noticed that the actuator motor is turning a full circle onwards (when recirc is off) and a full circle backwards when recirc is on. My understanding is that actuator turning range (actuator movement) must be a quarter of a circle when recirc is off and the same backwards when recirc is on; although i am sure. Anyone can enlight me on the turning range of the actuator motor ??? Is my assumption correct ??? Maybe the unrestricted motor turning broke the actuator. Please assist

 

Mine would also turn a full circle in each direction when I simply plugged the actuator motor in without it fully connected. Once I installed the assembly back together it would only turn a quarter circle and stop when the flap closed and turn the opposite direction a quarter circle to open the flap. The motor must sense the tension on the gear once the flap is fully open/closed and stop the rotation of the motor.

If yours is turning a full circle after you've reinstalled everything then you must not have the gears lined up or in the proper position to actuate the door properly. There is a flat part on the mating gear that needs to line up with the groove on the gear. I had to press the Recirculation button a couple of quick times to line the gears up properly.

 

i c......so my motor should be ok. I will try to align them by multi-pressing the recirc button and report back tomo.

Thanks for useful info!!!

 

Therock2........finished the alignment as per your instructions. Works like a piano now !!!!!! Many thanks your assistance

 

Thanks for the pictures! I pulled my actuator from the blend door and found the connector/gear sans the gear which apparently broke off completely. If you ask me, it is the prime example of planned failure in a design on the original part. I expect the newly designed part will fix my issue.