So I bought an '05 1500. I have had it about a month and noticed the fan wasn't blowing as hard as it should be. Having prior experience with the broken recirc door (my brother had an '06 ram), it was my first suspect. Sure enough that was the problem. The very tip had broken and the door had just fell and was blocking the airflow. After I removed the fan and door, I found the small piece that had broken off.

The Fix: You will need to remove the glove box and lower dash. There are several screws in it as it goes across the whole truck.
The recirc door: I drilled 2 small holes at the pivot point and twisted wire around it. This alone would probably be enough, but as extra strength I coated the end in epoxy. To re-install you will need to unscrew the door actuator and pull the white stud out. then replace the door, put the white stud back into the door, and replace actuator (make sure you align the actuator on the stud the exact way as you removed it or the door will not open/close correctly).

It's been a week and no issues

 

Had this issue with my Durango rear air.
Similar fix, post #19...............


https://dodgeforum.com/forum/1st-gen...ks-fine-2.html