This is why it is very important to make sure the axle pin and the door position are in line with how the door should operate both open and closed. Otherwise you set yourself up for the same thing to happen: over rotation of the axle pin by the motor, which breaks the door axle. I made sure this was correct by hold the door closed (pressed against the side facing the rear of the truck) and with the other hand, positioning the axle pin to be flush with its stopper as it should be when the door is closed. After I positioned and popped the axle pin in, I turn it both ways to ensure the door was functioning as it should on both sides.

Wow, that is much harder to explain in text than it is in person...


Heater treater is an excellent fix, but mega expensive for what it is IMO. To each his own.

 

I don't understand. The pin can only attach to the door in one position. There is no way to align anything. What are you talking about?

 

Thought I would comment on this since I did it this morning and this really helped.
The thing you forgot to say was grab your set of small hands. I had to use a dremmel to open up the access hole a bit because I couldn't fit my mitts in there with a screwdriver.
Thanks for putting this up or I would have just lived with it being broken.

 

LOL I could have sworn it was starred but low and behold, it is not.

 

Outstanding!! Will be tackling this today!!

 

Will this work on a 02?

 

Hope this reaches someone!! I am having the same problem but it is the 2 driver side vents that are blowing out warm air! Could it be the same door?

 

No. We were talking about the recirculation door. Your problem is with the blend door. Much bigger project.... Sorry.

 

Just pulled my broken door out. Now to take on the task. My dealer wanted 70 for the part so I will be going the online route. For now Much better airflow with it not blocking the motor. Thanks for the how to. This is gonna help a ton

 

Thanks for the write-up. I just finished with mine and it was actually easier than I initially thought it was going to be. I was very scared when I removed the glove box and was trying to figure out if my hands were going to fit or not. But everything went smoothly, except that when I pushed the new pin in, I heard something snap. I looked around in there as much as I could but did not see or hear anything. I put it all back together and it does work great!!! Hopefully now I can beat these 115 degree days. Thanks again