I've been procrastinating on repairing my 2003 DGC SE 3.3L that right now has no heat. Winter's approaching soon and it won't be fun without some nice warm air.
I've checked the coolant level, it's OK. Both input and output heater hoses at the firewall are hot so I don't think the heater core has any obstructions. I am fairly certain the blend door is stuck in a position to allow only cold A/C through. Prior to the problem initially seen last Spring, I had heat (HOT!) and over the course of 1-2 days it started getting flaky whenever I moved the manual temperature control dial. Then the heat finally quit, or more accurately I'd say it was stuck on cold.
I recently pulled some of the lower dash components off and looked at the blend motor and linkage on the driver side and the linkage end of the motor had what looked like a plastic geared wheel and there was nothing attached to the other end. I stuck my finger into a hole on the main housing(?) where the motor normally attaches and could feel the linkage that was likely once connected to that geared wheel on the motor. (Perhaps the act of pulling the motor off the housing made the blend door linkage fall off???). Of course, getting to it would take a major tear-down of the dash. There isn't anything in the Dodge Factory Service Manual to provide that level of detail so I don't really know exactly how the motor and blend door linkage come together to move the blend door. In fact, I couldn't even find the blend door.
I have not checked the actual motor itself, I'll assume it is OK for now since I *think* the linkage is the problem.
OK, long story short, has anyone pulled apart the dash and had to reattach linkage for the blend door? I'd like to get some ideas before I punt and take it to a Dodge service shop for a diagnostic estimate. Quite frankly, it doesn't look like a trivial task and may be a lot more involved than I want to take on.
My van is an SE model with a single zone heating system and there is only blend door and motor on the driver's side of the radio console.
So far, no responses and no solution, yet. The urgency to get it fixed hasn't been so great now that the family's daily driver is an '08 Civic. The van has been relegated to part-time driving use.
I tried to sell it but for the prices I have been offered ($2K max) I'd much rather keep it as a spare vehicle. It's still runs great and I know all of it's history.
Anyway, I made another attempt to diagnose the problem. So far I notice this:
- temperature gauge is normal, just below the 1/2-way mark.
- coolant level seems to be normal, both in radiator and in the overflow reservoir.
- upper radiator hose is hot.
- both input and output heater hoses are hot. The heater core itself is also hot.
- all HVAC control servos seem to be working, especially the temperature control servo. I checked each control individually and I could hear a servo whirring when the control position was moved.
- I ran the blend door calibration procedure, it operated in the normal time frame (under 2 minutes) and came up with no error codes.
- still no heat, only cool or cold air!
Has anyone pulled apart the dash to fix either the door itself or the linkage between the servo and the door? Or, has anyone had a similar problem repaired by a service shop? I'm tempted to take it to a dealership and spend the $90 or so for a diagnosis. Hopefully they will either come back with some relatively easy fix that I've overlooked, or come up with the same diagnosis as I expect to hear (blend door not moving due to broken door or bad linkage) with a repair price that isn't too outrageous.
Anyone have any similar experiences with the HVAC or a dash teardown?