These problems are not new -- just finally fed up with it...truck is awesome otherwise...nice little 2003 2wd 1 ton quad cab dually (six speed). The ONLY problem I have had out of it is the climate control system - not a dual zone system - I have searched throughout the internet and not really found any "sound" solutions so here goes (sorry if a little long)
- when running a/c - cold air on drivers side and HOT air on passengers side...went round and round with TWO dealers back when the truck was under warranty and neither could fix it. They were wanting to pinch heater hoses and all sort of weird things that IMO did not need to be done - (something was built incorrectly to begin with) ---then the kicker was when one of the dealers gave me a bullentin from dodge stating that for several year models it was normal for there to be a 12+ degree difference between the two sides (yes I lost it right then and there)....they had their piece of paper and so much for them fixin' it...the other dealer tried several times (they even worked on it after the warranty ran out (up till about 60k)---then I apparently waited "too long" between visits b/c the last time I carried it in they said it had been over 6 months since the last time it was in (hello - winter) and I would have to pay at least $500 (deductible).....that was the last time I have spent and time/$ on that problem (yes it is still doing it ---I'm cold and wife burns up :-0) any ideas?

- the other issue is now the "vent" selector switch has finally quit working...it used to have a mind of its own and switch to defrost or floor after about 5-10 minutes, but that hasnt happened in about 3-4 months ---and the past few weeks are reminding me of how long winter can be...hot air blowing at my face all the way to work.....one suggestion from a "friend" was to replace the climate control "module/panel" as the switch may have gone out...havent done that yet as I didnt want to just start throwing money around...any ideas on this un?

and yes the a/c clunks when it starts up also but I guess that can wait till spring....

guess its about time to spend some $$ on it ...as I do get 20 mpg :-)

 

my 02 1500 quad cab problem last winter was that when calling for heat, passenger side was warm and driver side was ice cold. I took the entire dash out to fix the problem and couldn't find the solution. What I found was that the duct work is set up for dual control (same mold to manufacture, save $). The flaps that control the flow to each side are connected and have one motor for both.
What else I found was that the heater core was the issue, it fits into the duct work with the back half heating the driver side. So what I did to fix it was flush hot water with high pressure though the heater core and that cleared the back half.
That gave me heat on both sides, your controls I'm not too sure about.

I flushed it out for about 15mins in the laundry tub with only hot water. You'll be able to do this without tearing your truck apart,if you got any plumbing skills.

I hope this helps

 

This sounds like the blend door problem, I'm going to see if I can find some info on it.