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.
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)