Originally Posted by Philmycrackin
MOPAR Blend Air Door
MOPAR Blend Air Door
The problem they are describing is not a blend door issue (the blend door adjusts the level of heat/cold, that's it!).
I've removed my heater dash/heater core twice in the last month, so I'm pretty fresh up on what does what.
Here is the color coding of vacuum lines going to the three different "vacuum door actuators" in my 1997 TJ SE, No A/C:
Blue & Yellow: Controls the door to the Defrost vents
Red: Controls the door to the cab/hand warmer vents
Brown: Controls the door to the Floor vent
My troubleshooting suggestions:
1) Check the vacuum line connector behind the glove box. Make sure the connector is secure and all the lines on both sides of the connectors are snug and there are no obvious cuts along the visible vacuum lines.
2) check the end of the vacuum lines where they terminate at the three separate vacuum door actuators (on the driver side end of the heater box).
3) If this all checks good, then pull each vacuum line separately at each location in #2 and check for vacuum when the respective doors are actuated, as I have identified by the color coding, above.
The above steps should troubleshoot 90% of the problems as described by TJ owners, above.
A couple of other notes regarding the heater and their levers, from hard earned experience with my 1997 TJ:
If you heater core is leaking, you don't need to take out the steering wheel/column as listed at STU OFFROAD for replacement; just support the removed dash suspended by a tie down from the large footmans loop above the rear view mirror (remove the mirror first)... it will save you 30-60 minutes of time, and prevent you from risking damaging your air-bag clock spring.
If you have a 97-11/99 TJ with the manual slider/cable for temperature control vs. the newer electronic knob and electronic actuator (either of which moves the AC Plenim Door via the Lower AC Panel Plenum Door Lever), than:
1) If you need to replace your lever (you snapped it off) DO NOT GET the Omix-Ada 17910.01 HVAC Door Lever; all online catalogs (Amazon, etc) says it will fit, but it will not... you will have to buy the more expensive Mopar Part # 4897626AA , which I have seen for $27-$35 each. I stopped buy a local Jeep Dealer's parts counter and they said that you couldn't just buy the lever anymore... you had to buy the blend door too... whatever... that part is currently available online out there at the time of this post.
2) Before you snap off you lever, lube the darn cable! (or if you are replacing the broken lever, do it too!). That slider/cable should move smoothly, without too much force... if it takes a lot of force to move that lever... STOP WHAT YOU ARE DOING! and lube the cable first (motorcycle store for a cable lube tool and a can of cable lube). If that doesn't solve the issue, then you might need to replace or re-align your blend door... don't snap off your lever (like I did) trying to force a misaligned blend door to work properly... it just cost me and extra $35 for a new lever (and i still had to take apart the heater box to re-align the blend door... and now replace the lever!
You can also trouble shoot a stiff lever, before you even lube that cable, by removing the cable from the lever... the lever should move freely and easily back and forth... don't try and force it if it doesn't.
3) If you plan on replacing your blend door, DO NOT get Dorman 902-326 part.: it is for the 99+ TJ's using the electronic actuator, not the cable/lever of the 97/98.