2000 dodge ram blend door wont stay on AC
I have a 2000 dodge ram 2500 gas 5.9L. when I turn on the AC the air will blow cold for 5-15 seconds and then I will hear a smacking of a door closed, and then I only have heat.
Here's what Ive learned so far: this problem is most likely due to the underbuilt plastic connector between the blend door and the actuator. Although the heater treater youtube video says that all second generation rams have the actuator accessible from outside the plenum/heater core area, this is not the case on my truck. I can find only three actuators: one for the recirc door, one for the control between floor/defrost and dash vents, and one to control between floor and defrost. these all work fine. There is an electric motor mounted on the bottom of the plenum box just above the passenger floor behind the glove box. This I am assuming controls the blend door. when I adjust the heat control, I am able to see the shank of the motor which goes into the plenum spinning. I understand this is shut off electronically when the voltage spikes due to resistance from the door being closed. It currently continuously spins. I put a reference mark on this shank and repetitively watched it turn as I turned on the AC. Every time the smacking noise happened and the heat kicked on that shank was in exactly the same point. I allowed the shank to spin 180 degrees from that point and then disconnected the wiring. I then idled the truck for about ten minutes with the AC running with NO problem. as soon as I started driving, though, the door smacked shut and heat came out. I next took it to get a quote on having a shop repaired it, which was $1000. the next morning, after searching everywhere for some detailed schematic of the inside of the plenum, unsuccessfully(so as to avoid hitting anything inside the plenum), I concluded I would at least try drilling a hole through the plenum and jerry rigging the door on AC for the summer, and promptly drilled right into the heater core (I think, it was a radiator in the plenum which spewed coolant). I epoxied up the knick in the radiator and am currently thinking of connecting the heater hoses together under the hood and bypassing the heater core altogether for the summer.
Any thoughts on whether thats a bad idea? I'd do the job myself if I could, but the manual says under AC it will not give a procedure as its illegal to expell freon into the atmosphere, and most literature online says you must drain the coolant and refrigerant. I have never flushed a radiator before. Is it hard or take anything specialized? What about if I had a shop drain the refrigerant, and then completed the work, or should I just pay the $1000?