no there is no play. If I put the heater control **** dead center and straight up and down, then start the truck. While the truck is running and I pull the fuse for the blower motor (actuator is on same fuse) then put the fuse back in, then turn **** to full heat it works wonderfully, if I turn **** to full cool it it works wonderfully. But when I turn it back to full heat it stays at full cold. It’s like it gets confused. Brand new actuator, and brand new coupler.Blend door has no play and moves very easily by hand. This isn’t a huge deal, but I can’t stand it that I can’t figure it out.

 

It’s not a mechanical issue. It has to be electronic or it wouldn’t go from hot to cold at all. If I remove and replace the fuse it will go back to hot to cold but won’t go back to hot unless I remove and replace the fuse again. Like I said it has me baffled.

 

I'm confused-- does it NOT get confused when installed and only gets confused when attached to the blend door?

 

This reply confuses me. Just read from the beginning of my post. Let me think on this some more.

 

ok I thought about it. When it’s not installed the actuator has a continuous circle of operation in whichever direction you turn the control ****, either left or right. It works perfectly when uninstalled and not attached to blend door. But when it’s installed when turned to heat it works fine, then when you reverse direction to cold it works fine. BUT when you reverse direction again to heat it won’t change, it stays on cool. This is about as clear as I can put it.

 

You may want have a look in the service manual but i believe the temp **** is potentiometer, This tells the actuator witch way to move. If there is dead spot in the pot it may stop the actuator from moving. I found this on the net...

 

well I’m ashamed to admit it but this picture means nothing to me. I know nothing about reading schematics. But what you said makes sense.
A while back I replaced the bezel on my dash and had to remove the temperature control panel to replace a vacuum hose. I’m wondering if maybe I did something to a connection? I’ll have to investigate this.

 

Ok there is a dead spot! If I turn it all they way Donn to cool it won’t go back up. But if I stop about a quarter inch from cool it will operate as it should. I can live with that! Thanks for your information, it helped a lot.

 

No problem, There may be some of the same info on the stickey for the blend door. If not there then the service manual will have it.

 

That sticky give out some false information. You do not have to remove the dash to fix a stripped out actuator, just remove the two screws and pull the actuator down. Remove the cracked plastic coupler from the blend door by pulling strait down. Replace with a metal coupler with metal one from http://heatertreater.net/dodge-ram-95-02