Originally Posted by weedahoe
Where are the pics and/or tutorial?
I suppose I could do that. Let me see... I'll have to "borrow" a few pictures found elsewhere but I'll add several of my own as well.
Recirculation Door Replacement for a 2006 Dodge Ram
1. Check to make sure it is actually your recirculation door. You can check that very easily by undoing the three bolts that attach the fan motor and then unplug it and pull it out. This is the circular looking deal just above the passenger floor board shown here:
And the motor removed:
2. Once the motor is out, which takes maybe 3 minutes and a flat head screw driver, lay on your back on the passenger floor board and look up into where the blower motor was. If it is the recirculation door that is your culprit, it will be laying right there blocking the air duct. Reach up and pull it out (while you're there, make sure to remove any other pieces or debris that may be loose in there). If it is broken, it will not be connected to anything. Once it is out, you will have full blown air now, but without the door in place, you will not have any control over closing out the outside air (which if it was broken, you didn't have anyway). Below is what the broken recirculation door looks like:
3. Now that you know it is the recirculation door, you'll need to pick up Mopar part number 68004226AB
. This can be found online for about $35 but no matter how you spin it, it is around $50 shipped so I just picked mine up from the dealership for $50. They do not sell only the door anymore so the part that you receive will actually be the entire Air Inlet Housing shown here:
All you need however is the door motor, the axle pin, and the door itself. Removing these from the part you get will help you understand how it look and feels under your dash, where your vision is limited so take note. To retrieve the parts you need from the new part follow these steps:
-1. Unscrew the two phillips head screw located on the door motor.
-2. The door motor is now free and will slide out and off.
-3. Now with a pair of needle nose pliers, grab the axel pin and pull HARD in line with the axle away from the housing. This is the most difficult step for most but if you pull hard enough, it will give. It is only held on with contact points.
-4. The recirculation door is now free so remove it from the housing (Note: in this picture, I'd already removed the door and put it in my truck).
Now that you have the door, the door motor, and the axle pin, you are ready to move on to step 4.
4. Remove the glove box. This can be achieved by depressing the upper parts until you see the rubber grommets as shown below: It falls right out.
5. With the glove box removed, you can look directly at the Air Inlet Housing (you should be familiar with what this looks like because you have a brand new housing to compare it to). It is on the upper right hand side view as you look into the glove box opening. There you will see the door motor and the screws that mount it seen here.
As you did with the new part, remove the two screws that mount the door motor. Note: I chose to replace the door motor also but it is not necessary so you can simply move on to step 6 now if you wish. If you wish to replace the door motor too, unplug it but don't replace it with the new one just yet.
6. Now for the fun part. After removing the door motor, you will see the old axle pin (usually white vs. the new black one you will replace it with as seen below).
Get in there again, as you did with the new part, with a pair of needle nose pliers and grab the axle pin firmly. You actually have a bit of horizontal space in there so again, pull FIRMLY inline with the axle away from the air inlet housing and it will pop out. You're going to have to pull HARD.
7. Once that's out it is time to replace the recirculation door. Go lay back down on your back on the passenger floor board and with one arm feed the new recirculation door through the HVAC tube back up to the top of the inlet housing where it belongs (as seen on the new part before you removed it). The wider side of the recirculation door's axle (the side that typically breaks on the older version doors as shown above on my broken door) should be on the driver's side where the axle pin goes. Feed the little end of the door axle into its socket and hold everything in line. With with the other arm, place the door axle pin in place and press the axle pin inward firmly until it snaps into place. NOTE: Make sure the recirculation door is closed (pressed against the side of the Air Inlet Housing that faces the rear of the truck) and the axle pin's rotation limiter (the black protrusion on the axle pin) is facing straight down toward the floor board. Once it snaps into place you can turn the axle pin back and forth assuring that everything is in place properly.
8. Now it is time to put everything back together. Put the new door motor back in by plugging it back in and replacing the two phillips head screws.
9. Put the glove box back by lining up the bottom mounting hooks, depressing the top where the rubber grommets are and putting it back in place.
10. Replace the blower motor by lining it back up according to the screws and plugging it back in.
Voila. A job the dealer would have charged you an arm and a leg for done within an hour for $50.