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Old 12-28-2009, 11:53 AM   #1
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HVAC assembly Heater door lever

Hey guys I am new to this site and am in need of help. One of the three hvac vacuum actuated door acuators on my 1997 tj is broken where the plastic arm goes into the air box assembly and it is keeping me from being able to use anything but the floor vents. I found the part online for $13.95. My question is has anyone had to replace one of these and how hard was it to get to? Did you have to remove the dash? Any help with this is appreciated!

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Old 12-29-2009, 08:24 PM   #2
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HVAC Box Blower Door Levers

Hi, I am in the process also and have removed my dash and split the mixer box. I removed the broken arms but have not found anyone that stocked them, the dealer keeps trying to sell me both halves of the box. Where online did you find the plastic arms? Thanks Chris.

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Old 12-30-2009, 12:18 AM   #3
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There is a write-up in jp mag forums on how to fix that arm.
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Old 12-30-2009, 05:28 PM   #4
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I found the parts at discountjeepparts.com but I am not sure if they are the right ones. There are 3 of those arms on the box assembly and dicountjeepparts only sells 2. I am not sure if two of them are the same part # or what. They are listed as upper defrost door and lower a/c door or something like that. They look like the right part but like I said, are two of them the same part? How hard was it removing the dash to get to the box?
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Old 08-01-2010, 08:45 AM   #5
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I ordered the upper defroster control lever from discountjeepparts.com.The control lever that they sent me came in a plastic baggie with a label that read "17910.02 Defrost Up Door TJ". It's the wrong one. I screwed around with it for an hour before I figured it out. From the picture on their web site it looks like you need to order the 17910.01 Hevac Door Lever for Lower AC Panel Door for 1997-06 Jeep Wrangler TJ. That picture looks exactly like the broken lever that controls the defroster on my 1997 Jeep Wrangler TJ. Hope this helps people.
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Old 06-21-2011, 06:20 PM   #6
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I have a really crazy question here.... the same little black arm is broken on mine. Do you think it would work if I glued it back in with a plastic epoxy??
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Old 01-25-2012, 11:18 AM   #7
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Quote:
Originally Posted by katycamp View Post
I have a really crazy question here.... the same little black arm is broken on mine. Do you think it would work if I glued it back in with a plastic epoxy??
If you remove the broken part first before gluing it I'd say it might work for a while. It's worth a shot anyway. If you try gluing it with the broken part still inside you run the risk of gluing the whole thing to the housing. If you get a 3 inch deck screw you can screw it into the broken piece a little bit and pull it out with a pair of pliers. That's what I did with mine and it worked.
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Old 01-25-2012, 11:27 AM   #8
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Quote:
Originally Posted by Signal26 View Post
Hey guys I am new to this site and am in need of help. One of the three hvac vacuum actuated door acuators on my 1997 tj is broken where the plastic arm goes into the air box assembly and it is keeping me from being able to use anything but the floor vents. I found the part online for $13.95. My question is has anyone had to replace one of these and how hard was it to get to? Did you have to remove the dash? Any help with this is appreciated!
No, you do not have to remove the dash. Get a 3" deck screw and screw it into the broken piece still inside the air box. If you've got it screwed in enough you can pull it out with a pair of pliers. The new one should have a flat spot in the splines that line up with the door so you put it in correctly. Then all you do is push it in until it snaps in place.
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Old 01-25-2012, 11:37 AM   #9
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I'm dealing with this same problem in '98 right now. From what I've found you need two different levers for the top two vacuum actuators. I ordered the upper defrost lever and it fit into the hole for the middle actuator. I'm guessing I need the lower A/C lever for the top whole. This is a bit odd because the top hole, the one that kind of sticks out past the middle hole, is the defroster door. The middle hole is the door for the upper vent by the radio. The bottom is naturally for the feet."

I went ahead and took the whole dash out thinking the actual door was broken off. Turns out it wasn't. But I'm going to try and take a bunch of pictures and do a nice write up on how to take it apart when I put it together.
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Old 01-25-2012, 04:50 PM   #10
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anyone have a diagram of what all this looks like under the dash? or a picture? this happened to my jeep except its stuck on defrost so I got no heat in the cab! is really sucks!!
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Old 01-27-2012, 11:35 AM   #11
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This is with the dashboard removed. The top opening is the defroster vent. It is controlled by the middle vacuum actuator. The top actuator controls the upper vent by the radio.
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Old 09-18-2012, 03:31 PM   #12
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Many thanks to GJ7GoldenEagle for the idea about the 3" screw to remove that broken piece of plastic on the door lever arm. It worked! Saved a lot of time. Now, the new part is on the way and it should be a quick repair. I live in northern Michigan, and defrost is a necessity! Thanks again. I am new to jeep ownership, and the advice on this forum has been really helpful to me and my '97 TJ. Thanks again.
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Old 11-22-2012, 12:19 PM   #13
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Dash Removal

Here is a write up I did on how to take the dash out in case you ever decide you want to try it. Hopefully it'll help someone out.
http://www.wranglerforum.com/f5/dash...al-144267.html
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Old 02-15-2014, 03:26 PM   #14
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hi guys new here i just bought a one owner 1997 jeep wrangler but its blowing cold air replaced the thermostat already any other suggestion

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