Ive seen about 4 or 5 threads on this now. Figure I would help everyone out and post how I did it WITHOUT tearing the dash out. A little bit of patience and removal of the glove box door is all thats needed. Here is what I wrote on other threads about it.
If you already have the replacement door kit from the dealer, look over your parts really good and you can see how everything works and what im talking about.
Also be sure its the recirc door causing the problem. There are 3 doors:
Mode door - selects the direction the air is going to blow ie: defrost, feet, ect
Blend door - blends hot and cold air to your selection
Recirc door - choice between fresh outside air or in cab air. You'll know if this is the culprit if your blower motor is on high and hardly blowing.
This is a very simple fix. I had to do it on my 06
- First, lay on the passenger floor and you'll see the blower motor, remove the 3 screws that hold it on and unplug it.
- Now reach up inside the opening with your left arm and youll hit a loose piece of plastic laying there. Thats the broken door, simply flip it vertical and out the hole.
- Next remove the glove box door, you'll see tabs on each side, just squeeze the door past those tabs and the door will want to fall past its normal opening position, you'll see that the door just lifts off.
- Next using a flashlight look up inside the dash and youll see where the recirc door housing is. It looks like a checkerboard layout. To the left of that is the servo that drives the door, unplug it and remove the 3 screws that hold it on.
- Next comes the only difficult part. There is a while nipple that hooks the servo to the door, it stays in once you get the servo off. Its held on with 3 little push clips that are kind of a pain to pop out. Once you get the white nipple out make sure there isnt any other parts left in there before you start putting new pieces in because they can fall into the blower motor once you kick it on, cause it to go off balance and break things lol I know, Anyways your new recirc door comes from the dealer with a new blower box ect ect, all you need is the door, the white nipple and the servo. Youll see how the nipple drives the door, Its been a while since I did this so If i remember right you have to put the piece on the door, then put them both into place at the same time, make sure the servo is lined up with the nipple piece, screw the servo back on. It wont mount flush if it isnt lined up.
- next plug the servo back in, and remove any tools and stuff from the area and turn your key to the ON posisition and turn the heater on (you dont need the blower motor hooked up yet) switch the heater from outside to incab a few times to double check its functioning right, you will have a clear view of it. Servo will move pretty slow.
- if everything is up to your standards, put the blower motor back in after inspecting it for broken blades and junk that might have damaged it, put the glove box door back on and you should be good to go!
Took me about 1.5 hour to do without any guidance, hopefully with this you can get it done in less time!! about a $40 fix (I think.. might be $20 now that I think about it)
This should help out alot of guys from having to deal with warrenty and not having their truck for a day and help avoid all this nonsense of pulling the dash out. If I can get my big sausage arm in there, shouldnt be no big deal for a regular guy.
The blower motor in the mounted postion
Blower motor removed
Glove box popped
Glove box hinge
White clip that links door to servo that needs removed as suggested use a little socket to compress the tabs
Install the new door, white clip side first then snap the other side in. Its best to try and position the servo in a straight up and down postion to make it easier to put the door in
Recirc door open
Recirc door closed
Its pretty straight forward, just a view of some of the parts and pieces here to help you guys out