Okay - I removed all the vents and actuator motor and confirmed it worked. Then I removed the glove box and cut into the heater box. Accessed the old door and confirmed it was broken - removed and I have the Doorman repair kit with the new door and cheat (metal bottom sleeve to put on actuator) for installing the new door. Issue the broken piece of the door i can not get out from the old - i have tried everything... pushing from up from the bottom, pliers on it - nothing. It turns the 60 deg and wont budge. HOLY MOLY .Any suggestions.....

Thanks

 

Additionally the door was broken/sheared 1-1.5"up from the bottom of the door.

 

Weird... I used the same kit and mine came right out with zero issues. I just reached in there and pulled the chunks out. In fact, some of it fell out with the actuator motor.

 

yeah thats what i have read on several threads and videos....unfortunately not my case - well when it stops raining i will try again. thanks though - happy new yr

 

Did you get it?

 

negative - tried for ~1.5 hours and still nothing. Went to Home Depot last nite and bought a hacksaw blade and I think it will be thin enough to get under the bottom sleeve to tediously saw it off but I will try this week. I tried to dremel is off but was doing more damage then accomplishing anything.

Thanks for checking back and let me know if you have a breakthrough idea.

 

i had the heater core replaced a few years back at dealer ship - i wonder if they installed it wrong or the part is covering up the bottom of the door.

 

okay i finally got it - in the pictures and the videos on line a couple of lessons learned.

If your blend door is broken but not in pieces it is not easy to remove. My was broken 2 inches up from the base and still seated in the bottom hole and in still turned. The bottom of the door is turned and "locked" into the base of the air box and you can only move the piece 60 deg and you will have to cut it out - you can not pull it out. Due to the limited space a hacksaw blade worked best.

Second getting the door to seat back in the hole is not easy as you will have to seat the top into the guide and then place the bottom and turn it so the half of the bottom is locked in. After the door is in place the rest is pretty easy. I will try to upload pics of my delima.

I got heat thats all that matters.

 

Glad yo got the door fixed!

You sure on that last line "I got head thats all that matters." ?
I never had that experience fixing my truck. Can you instruct me how to make that happen?

 

my bad - typo - fixed above