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3rd Gen Ram Tech2002-2008 Rams: This section is for TECHNICAL discussions only, that involve the 2002 through 2008 Rams Rams. For any non-tech discussions, please direct your attention to the "General discussion/NON-tech" sub sections.
I am trying something that may or may not work. I always use one notch from full heat or full cold to keep the door from closing too tight and stressing the plastic. It may or may not work, but it is worth a shot.
Check out heatertreater.net for a video series that details all the various blend doors and troubleshooting. 3 vids, 6-7 mins each. Well worth the time!
cheaper easy fix for DIY
