My blend door broke a couple years back and here's my poor-man fix that still works(knock on wood). My theory was that I couldn't break it any more!
Remove plenum cover(center cover, under dash). You might also need to remove the floor ductwork, but I think you can get by without doing so.
Take a Dremel with a cutting wheel and cut a nice big hole in the heaterbox(it's black) above where the blend door actuator is (down by the floor). If you don't see it, turn the key to on and with the radio/fan/etc off(quiet), turn the heat from hot/cold...with your head down there, you'll hear it turn if it works. WHo knows, maybe your actuator is the problem...that can be unbolted and a new one put it.
Also cut through the plastic that was behind the glovebox. Once the box goes back together later, you'll never see it anyway. Here you can cut a massive hole, big enough to reach your arm in.
Once the holes are cut, you can see inside with a flashlight if the door is broken. Gotta love plastic parts!!
I was able to feel around, gather my pieces, clean them up, then epoxy them back together before assembling it all back inside the heaterbox on top of the actuator spindle.
Give it a day to dry before doing anything with the truck. once dry, try turning the heat/cold ****...you should see the door move. If everything is working again, take some JB Weld or some more epoxy to glue the "windows" of the heaterbox back on. Reassemble the floor plenum and reinstall the glovebox.
You should be back in biz without coughing up $1200 to the dealer for their fix. If it doesn't work, well...it was worth a shot anyway. Goiod luck!
Originally Posted by iowaredneck
Thanks for the help. Is the blend door that hard to change?