I did a search on this (caravan forum only) and only found a few threads mentioning the recirculation door, but they were primarily focused on the actuator, not the door itself. So, I decided to share my experience with this fix since it seems to be a common issue (or at least used to be) on Dodge and Chrysler vans.

Unfortunately I didn't take pics at the time but I don't think it's difficult to visualize what I'm describing.

Just as FYI - I'm a professional mechanic - sorry, the politically correct term is "Automotive Repair Technician" - with 2.5 years professional experience, but I've been doing mechanic work unprofessionally for about 20 years. ... ... I'm not really sure why I thought that has anything to do with this thread.

Anyway, back in January, my sister asked me to look at her 2009 T&C because the windows were fogging up during her morning commute, to the point that she'd have to crack the windows to help defog them. It was still winter so that was quite inconvenient.

Although I did find that the thermostat was partially stuck open and the engine wasn't getting up to temp, replacing it wasn't the source of the problem. I noticed when I would press the recirculate button that the indicator light on it would flash and there wasn't the usually noticeable change in pressure coming from the vents. I checked the HVAC module for codes and found one related to the recirculation door - I don't recall the exact number, but the description was something to the effect of "Recirculation door travel too large."

I removed the glove box and watched the recirculation door as I used the scan tool to command the recirculation door to move - the actuator began spinning but the door was not moving. The actuator continued to spin in circles until I shut it off.

The problem was not that the splines on the actuator or the shaft had stripped. The door shaft had broken just inside the "cage" of the air inlet housing on the actuator side.

Of course, for all of the googling I did, I couldn't find JUST the door. I could only find the air inlet housing assembly - can't remember which website I got it from but it came with the housing, recirc door and actuator.


Now, onto the actual repair process.

All the service information I looked at stated the HVAC housing assembly had to be removed in order to replace this part. That meant pulling the entire dash and instrument panel assembly, recovering and recharging the AC and draining and filling the coolant - basically an all day job. Although I did have access to all the tools and equipment necessary to do this (and it wasn't the first time I'd removed an HVAC housing either), it looked like there was enough room to remove the air inlet housing without pulling the entire HVAC assembly, so I decided to give it a go.

Removing the torx screws that secure the housing to the HVAC assembly wasn't too difficult. What the above picture doesn't show is there is an "ear" on top of the housing that is secured to the dash with an M6 bolt - I had to remove the upper dash pad to access it, but even so, it only took about an hour to get everything apart.

Unfortunately, it was not meant to be. For as much wiggling, pushing, pulling, twisting, etc.... the air inlet housing would not come out while the dash and HVAC assembly were in place. And then it dawned on me that I didn't NEED to replace the entire housing - it was just the door.

I was able to flex the recirculation door enough to remove it from the air inlet housing and pull it out from between the inlet housing and HVAC assembly. I did the same to install the new one. I used the new actuator that came with the new housing just to avoid trying to re-align the old actuator in the right range of motion. Once I got the inlet housing reinstalled, I tested the fix before reassembling the dash and it worked normally.

The inlet housing assembly cost about $70 with shipping. Even though I didn't install the new "cage" I considered it well worth the cost to turn a day long job into a 2.5 hour job from start to finish.

I thought others might like to know that it is possible to change the door without all the hassle.

 

I don't know how you did this but I got to say it's amazing there are none NONE nothing online explaining what you did not pictures videos. I really would appreciate some help on this and wish you would email me so we can chat. Please let me know if it's possible.