Hi. I'm brand new here. 03 Dakota 4.7L QC 4X4 5Spd Manual.

I've read all over about people not getting any blower air anywhere but the dash. (defrost)
I'm just the opposite. I get air everywhere BUT the defrost, and this is Saskatchewan, Canada, where defrost is almost required by law.

I have been under there and taken the entire mechanism apart.(a very flimsy and poorly engineered mechanism btw. seems really cheap and hastily put together)

These are things I know:
Mode door actuator is functional, though suspect weak.
Mode door itself can be manually opened/closed by laying on the driver side floor and reaching way up and flipping the cam with fingers.

The mode actuator motor is the closest one to the drivers side. While laying there and watching it while cycling the control, it appears that the actuator powers out before the job's done and can't quite get to that sweet spot where the door actually opens or closes. (there is an area of stiffness in the cam travel, when I operate manually, I can feel it move easily, then hits a slight stiff spot just before the "thump" of the door functioning.)

The entire assembly, from actuator to cam disk to link rod came tumbling down into my face while I was taking it apart. I'm 67.33% sure I have it back together right, but I've found no exploded diagrams of the proper synchronization of doors, cams, disks and actuators. If anyone has one, I'd sure appreciate it.

The connection between the link rod and the cam at the top (defrost door) really seems chintzy and cheap. I don't know it it's supposed to be all sloppy like that or if the pin has worn the hole into a slot.

I'm stopping at the dealer today to ask about a replacement kit for this actuator linkage system. Somewhere I read that there might be one, but it's not found online if there is. I gave up looking.

If anyone out there has some detailed drawings of this system, from actuator to the defrost door, I would sure be in debt to you.

Advice also welcome.

 

I have never seen a post showing these controles for the newer 2001 and up HVAC Box and the service manuals dont show it very well also just a general pic of the area nothing detailed

 

Anybody have experience in putting this assembly together?

I figure there's got to be a trick to getting the 'timing' right. This one actuator seems to operate at least 3 different gates.

Doesn't help that I have a big head that doesn't fit well under the dash, and eyesight that has difficulty with close up detail. lol

 

I found something that may help if you can understand it

Go here and download the 2005 Dakota service manual http://uploading.com/files/2m59f83m/...ND.SM.pdf.html

Look in the Heating and airconditioning section

 

Downloading. Thanks very much!

 

hmm... they've changed quite a bit. That diagram doesn't look like the one in this truck.. but hey, I really appreciate your help.

 

looking in my 01 FSM, I dont see any illustrations of the actuator/door?

 

That wouldn’t help anyway he has a 2003 Dak very different in many ways they don’t show you much in the 2004 FSM also just general pic's nothing detailed

The 2005 FSM I think is the one that will be the closest to what he has but it’s complicated stuff only 00DakDan can figure the electronics out on it the door is in question if any Pic is available

 

Sometimes the Ram or Durango is very close to what is in a Dakota of the same year looking at a ram fix may help like this

Well crap the link never works this forum keeps mashing the link no matter what I try!!! I guess they dont like this forum so they ban any links to it.???

Ok try this below thats a pic of the other forum

 

Look here you may find some info air blend door fix

http://www.cumminsforum.com/forum/3r...goes-hvac.html