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post #1 of 12 (permalink) Old 05-16-2019, 11:23 PM Thread Starter
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Dash Removal/Heat/A/C Door Replacement

Does anyone have a simple, straight forward way to remove the dash (2003 3500 Dually). I know it is a daunting job, but.... must be done. I have to replace the doors, because as it is I get almost zero Heat, A/C through the vents.
Thanks in Advance.


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post #2 of 12 (permalink) Old 05-17-2019, 12:26 AM
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I have done it. Did the blend door usa swap. My HVAC actually works now. If you go on youtube there is a guy there who did a good job showing what needs to be done to do the work.

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post #3 of 12 (permalink) Old 05-19-2019, 09:11 AM
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This may help although it's specific to a later MY. Also, IIRC, the newbies guide includes FSM's.

https://www.blenddoorusa.com/pages/i...n-instructions

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post #4 of 12 (permalink) Old 05-20-2019, 10:53 PM
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How long does this repair typically take to do? I think mine may have this issue.

John

2007 2wd 2500 Laramie crew cab 5.9/auto
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post #5 of 12 (permalink) Old 05-21-2019, 05:38 PM
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Keep us posted on how it goes. My local guy quoted me $700 and he'll do the heater core with a same day turnaround. He can have it for that, i'm always tempted to do it myself though.

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post #6 of 12 (permalink) Old 05-22-2019, 10:18 AM
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Quote:
Originally Posted by IH8CALI View Post
Keep us posted on how it goes. My local guy quoted me $700 and he'll do the heater core with a same day turnaround. He can have it for that, i'm always tempted to do it myself though.
That's cheap...the Blend Door USA kit is $320. A heater core is around $100 and change. $280 for dash R&R, vent box rebuild labor, AC refrigerant pump down, reclaim, recharge system, shop supplies and overhead....doesn't leave much for profit. Actuator replacements might be a good idea and duct/opening gasket replacements may be needed. More dollars....

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post #7 of 12 (permalink) Old 05-22-2019, 02:47 PM
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I'm sure the quote didn't account for the cost of the doors, nevertheless it's tempting. As mentioned in the YouTube video though, if you need new foam/weatherstripping as shop probably won't take the time to replace. Same goes with the condenser anti-rub guard that goes around it. There's no sure way of knowing it was done right unless you do it yourself.

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post #8 of 12 (permalink) Old 05-23-2019, 06:47 AM
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Quote:
Originally Posted by IH8CALI View Post
I'm sure the quote didn't account for the cost of the doors, nevertheless it's tempting. As mentioned in the YouTube video though, if you need new foam/weatherstripping as shop probably won't take the time to replace. Same goes with the condenser anti-rub guard that goes around it. There's no sure way of knowing it was done right unless you do it yourself.
Your last sentence is so true. Trustworthiness seems to be a thing of the past at times....that's unfortunate.

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post #9 of 12 (permalink) Old 05-23-2019, 06:10 PM
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Well, tonight's ride home just advanced my addition to the list of Blend Door customers. My AC is more like a heater.....the compressor kicks on and off when the "snowflake" button is operated. No cold air, none, zero. Last season my doors were acting up and this year AC performance was grim. Now it's really grim.....

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post #10 of 12 (permalink) Old 05-23-2019, 10:57 PM
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It will be winter soon....
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post #11 of 12 (permalink) Old 05-24-2019, 12:53 AM
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I can do a full rebuild in about 4 hours by myself, including the evac, disassembly, rebuild with new parts, and recharge. (BTW, I'm the guy from the video)

A few extra things to consider:
  • Replace the heater core and evaporator while you're in the box already. It would suck to have it go out and have to do the entire process again. The best quality I have found so far is stuff from GPD (Global Parts Distributors). I acquire it from Amazon. I've used several of the chain store brands (4 Seasons, Murray, Spectra, etc.) They're literally the exact same part and are of inferior quality than OEM or GPD.
  • Actuators, only utilize OEM actuators from Dodge. All aftermarket actuators that I have came across are inferior to the OEM parts.
  • Get foam to seal the outside of the box. I tried weatherstripping in the videos and it whistled while driving. I later pulled the dash again to replace it with Foam.
  • Make sure you recharge the system by weight, not by pressure. Don't use the disposable cans from the parts store, it's impossible to get an accurate charge that way. Find somebody with a good refrigerant machine (I use a Robinair 34788NI) that can properly evac and charge everything.
  • While the HVAC system is apart, it's not a bad idea to put a new accumulator/dryer on the system. You will sour the old one with moisture when you have it apart.

If you have any questions, I'd be happy to answer them.

John
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post #12 of 12 (permalink) Old 05-24-2019, 12:25 PM
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Quote:
Originally Posted by davo727 View Post
It will be winter soon....
That is very true too.....But knowing how my luck seems to go, come winter time, the AC would work great and the heat side would take a nose dive....

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