DIY fix for Jeep Cherokee A/C Blend Door Failure

Like most DIYers I see a problem and the last thing I think about is "where do I take this to get it fixed?" I instead ‎look at a problem and try to outwit traditional solutions. That being said, when I didn't have heat in my Jeep Grand ‎Cherokee (JGC) during our first cold snap I naturally went online to diagnose and solve the problem. What I ‎discovered was this is a very common problem with my model of JGC (1999-2004). I love my Jeep, but the person that ‎designed this blend door actuator system needs to find new work. The design is inherently weak, and relies on a ‎calibration phase that puts intense pressure on the weakest points in the system. Not wanting to repair the faulty ‎design with the same OEM design, I set out to reverse engineer a long-term solution

This website was among the more helpful sites as it provides Jeep's Repair kit instruction.  Thanks for a well thought out site, and permission to borrow content.

http://www.denlorstools.com/autoblog/2010/03/jeep-grand-cherokee-dual-zone-blend-door-repair/

This site does a good job of where and how to cut, so I will not re-invent the wheel.  I'll show you my solution to the kit from Jeep.

Total Cost of Project:
$1.76  Mending plate ($0.88 x 2)
$3.36  Hinges ($1.18 x 2)

Required Materials / Tools:
4  - 1/8" rivets
1  - Rivet gun
hacksaw or rotary tool (the hacksaw requires more patience than I possess)
Drill

Step 1 Problem...

I was able to remove and manipulate the outside most blend door actuator, connector and door without any issue. I ‎could have fabricated all new parts reasonably easily, however the passenger side control would not have worked. ‎So I worked within the OEM connector parts to ensure dual climate control operation.
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I decided on a standard 3 inch door hinge as my new pivot point. This stamped steel piece should be more than ‎sufficient to withstand the calibration forces. The door is a reinforcing plate typically used on decks and truss ‎frame construction. These both will be very easy to find at your local home center. The truss plate is found in the ‎pressure treated section.‎  You will need 2 of each to complete both blend door repairs.

Comments

[tallan1]

I just wanted to say thank you for this, it saved me about $160. I spent less than $20 and about 2 hors of my time. If I could just add, the hinge that I used was one that the pin just slid out of , so basically one less step.