I think what's contributing to these gears.Breaking is that the blower door is getting stuck on the ceiling that's insidethe h.V a c unit and once that gets stuck , the gear has to overcome the force and it just breaks. i noticed , you mentioned you broken a number of these. there is a number of videos on here showing the issue with the ceiling and the adore being stuck.

How long did you leave it, and when did you dig it up to find no potatoes?

Great thanks to you doing this video. My ‘14 gear failed and I was looking for the how-to. A few out there BUT not much help…yours gets the Oscar👍 Thank you!!!

My blower door appears to be jammed. When I had it apart before it would swing loosely not it won’t budge

Just ordered the Dorman parts for this repair on my 15GC. On the Dorman website it says that the parts now come with an alignment tool? Not sure exactly what it is, but I'll see when the parts are delivered. Dorman's site said they started including this alignment tool after FEB of 23.

This job is an absolute nightmare, mostly because of that difficult torx screw. Once you get it out, do yourself a favor and go to your local hardware store and buy a couple #8 x 1/2 sheet metal screws. It will be easier to screw in, and if you ever have to do this job again, it will be a hell of a lot easier to remove them in the future.

THIS VIDEO ^^^^^ This is the bible for getting this job done. By far the best step-by-step out there, A few additional things I ran into- 1.) the knee airbag isn't covered at all here. If you have a knee airbag, everyone says disconnect the negative battery terminal since you don't want it blasting in your face. Some say 2 minutes, some say two hours before the system discharges. I let it rest for 30 minutes. I found more tips here file:///Users/johndelgiorno/Downloads/WK2_Knee_blocker_airbag_removal%20(1).pdf. 2.) Apparently its a known issue that the blend door gets stuck and that's what causes the gear to break. Indeed, mine was stuck. Search online and you'll find different methods of freeing a stuck blend door- I got lucky and was able to pry it loose with a plastic tool (don't damage the gear!). This is a great tip on how to make sure it doesn't get stuck again- kzbin.info/www/bejne/gIK6amZ4hdqVfcU

Just did this today. And lost the top bolt. And had another one. And still can’t get it back in. But the one bottom bolt holds it in there nice and tight. I might just keep the one bolt in So it’s easier next time

same problem, the blend slide was stuck on cold too when i removed the broken gear. that's why the gear was broke i'm sure. i had to heat the vehicle up to unstick the blend door, thankfully it moved. tks for the video. p.s. I did grind down a T15 along with a 1/4 inch ratchet wrench

Thank you.

Replace the torx screws with 8x3/4 hex head screws. Much easier out and in,

There ya go….complain about having to replace the flimsy plastic parts so often then immediately explain how you bought the cheap chineseium parts to save $10. Solid logic there, sir.

So I replaced the gear on driver side actuator for blend door. I disconnected battery for 6 hrs. I still do not have cold air from drivers side. If I crank heat up to max, it does get hotter, but when I lower to minimum, the heat changes but does not get cold. Don't know what to do anymore. Passenger side works properly

Use a step bit and drill a hole in the metal bracket and that top screw becomes a breeze

This is how I removed that screw. kzbin.infovFdX_1H2aAo?feature=share

Thank for the video. I got the tool you made, amazon has it for 13 dollar.Really help me out a lot and saved 500+ dollar in labor. Now I need to figure out air suspension service/repair warning. Love the Jeep but 150K miles so much repair cost. I even forgot the list of items repaired. past 3 years I spent good 5K on repairs. Mine is 2012 GC Overland.

How did you get the actuator to line up with the cog out of alignment? Did it turn freely?

Hey man we appreciate this a lot this came at the perfect time bought a 2012 overland from a dealer and don’t wanna hear them asking outrages prices for this repair and best video on the issue forsure!!!!

Great video. The best on this issue. Thanks

Adding a spacer to the actuator gear stopper might help if you're having a chronic issue, because the blend door is actually getting jammed: kzbin.info/www/bejne/gIK6amZ4hdqVfcU

If you need the passenger side, check out kzbin.info/www/bejne/boDFl4xmqMiNrc0. I'm sure there are others, but youtube put that one on my homepage.

That turned out great!

Beautiful. Love this...our backyard has never looked this interesting.

I agree. Equipment's fault.