2001 Chevy Tahoe Blend Door Actuator Replacement

I have a 2001 Chevy Tahoe where the defrost selector in the dash doesn't work - it only blows how air out the front vents. In this video, I locate and replace the mode door actuator - not to be mistaken for a blend door actuator, and replace it. The replacement part is a Dorman 604-113.

[@FrancoJara-vw7uw]

Thank you so much Now i'm resdy to do the job Great video and tips

[@curtvantress529]

Great video, Manny. I reviewed quite a few other videos before finding yours. Your video is the only one I found that offered a thorough explanation of all of the challenges I had faced in my attempts and a number of others I would have faced if I had decided to press through. Thanks for the tips.

[@findingneutral]

I must ask before I even go buy the new actuator for $76. Your experience sounds exactly like how my experiences go trying to fix stuff. If you had to do this this all over again, would you just take it to the shop instead?

[@UtahDelaCruz]

Nope. It was still cheaper for me to do the work than to pay a shop. It just took longer than I would have liked.

[@findingneutral]

@@UtahDelaCruz My shop wanted $300. Needless to say I will be doing it myself as well. Thank you for shattering this tutorial with all of us so we have some insight. 👍

[@bradsellers8691]

Good vid man!!! I just did my 01 Tahoe today..Top screw comes out very easy and fast with a 1/4 inch air ratchet and a 7 millimeter long socket for anyone viewing this vid for help..Thanx!!!!!

[@davidrichards2048]

Replaced the AIR door actuator on my 2001 Silverado today. Just a few tips. 1) this actuator has nothing to do with the temperature!! Part number is 604-113. This actuator controls only where the air is distributed; floor, vent, defrost, etc. No panel to remove just the floor heat duct by the driver's feet ( 1 fastener). I used a tiny 7/32 box wrench for the top screw that Manny described. It's a pain but I couldn't get it off with a socket due to the metal plate. My biggest headache was removing the actuator after the screws and harness were removed. I finally pulled out the entire actuator and plastic plate assembly. Take some time to see where the white sprocket is and pry that gently forward while slipping the plate off. Once removed the old one slipped right off and the new one on without having to drill out the center. Install is just the reverse. Make sure the white teeth line up with black ones. When you turn the key the unit will adjust and hopefully work like new! Good luck.

[@RG-hn6dg]

You saved me tons of time doing this on my 2001 Suburban 2500. I bought a 1/4" ratchet wrench instead of using a normal wrench. I also use a 7/32" hex nut driver instead of a regular socket.

[@justjk8094]

I cannot thank you enough for sharing the little bit of knowledge. But please re-title the segment to say "...Mode (Vent) Door Actuator...". The blend door is located under the passenger side of the dash. The actuators are exactly the same part, just installed in two different places to do two different things. Again, thanks. If I am ever in Utah, I owe you a dinner or drink.

[@Linc5150]

Had to do this on our 2002 'Hoe yesterday - this video helped me anticipate and prepare - thanks! If I can add anything to the discussion to help the next guy, here goes: *Lower dash screws are 7mm. Three trips to the toolbox to figure this out for me. With a beer break in between. *Servo actuator is held in by 7/32, or 5.5mm hex head screws. Go out and spend $10 on a "quick change nut driver bit set" to save yourself the headache of dealing with that upper screw!!! Thankfully I have a set... I used the 7/32 bit, along with a 1/4" gearwrench (ratcheting wrench) to crank on the bit to loosen the screw first, then it unscrewed pretty easy using just the bit and my fingers. *The metal OEM servo "coupling" separated from the body of the servo actuator during removal, getting stuck on the end of the blend / mode door's cam plastic shaft - took a little extra finagling to remove it. *The problem you describe with the Dorman actuator's internal splines looks like a mfg defect. I noticed that there were a few teeth that still had "flashing" attached to them - which prevented it from sliding onto the cam's plastic shaft. Seems like a soft metal, as a quick cleanup with a tapered reamer was enough to get mine to slide over the plastic shaft on the blend door cam/cog. (Your drill bit suggestion works the same way.) *lots of extra light under there really helps!!! thanks again!

[@onthelake9554]

Change Video TiTle ! Not Blend but MODE actuator is what you replaced . Blend is for temp only . And you can get the "hard to get to bolt" out with a 7/32 socket on a universal joint and a 12" extension in 15 seconds .

[@drewsquickfix]

Check other videos guys. You may not have to Reno the upper dashboard. Its different on other trucks and each video is different. Still a well done video thanks for posting.

[@jefftolen1207]

Thanks for the detailed descriptions. I had the same issue of defrost blowing through the front vents and vice-versa.

[@fletchmanful]

hope this works ,have replaced everything but compressor , thanks for info

[@arcorob]

Very helpful. It appears taht shaft is keyed (in other words not round but the shaft must align yes?) So is there a preferred start setting to get it to line up (liek set it for defrost or do you have to guess the alignment ? Thanks...BY The way , you were referred on Amazon...LOL

[@zminns]

Thanks for the video. It did help because it told me to take to mechanic and pay the $300 - 400 to fix. Yeah (this me crying).

[@UtahDelaCruz]

+Zepther Minns It's a tough job - sometimes it's better to pay someone. I should probably do that more often.

[@zminns]

Dumb design. Manuf know how to stick it to us.

[@BamaPewPew]

Good lord, what’s your mechanic charge? $300 an hour?

[@davemarkellos6910]

Awkward tools??.....does cutting a Phillips head screwdriver handle in half with a circular saw qualify as awkward.....what a pain in the F_##ing a$$

[@harryb4366]

you said shaft- he he

[@elchema91]

Some things I learned doing this job. After you take out the fuses and put them back I notice that the actuator goes to defrost mode when turned on to recalibrate every time, so I left my setting to defrost on the dash even though when u install the new actuator it's on floor mode i believe. You can open it up and realign the gears if you mess up. Had to open it up plenty of times before i got it correct 😅. He's right about drilling out the splines will make it easier to remove an attach the backing plate. I first installed the backing plate, then i aligned the actuator and bolted it on.

[@robertfrank8293]

Used this video to help me for the 2003 LS Z71 Silverado. Tip for anyone watching. Go ahead and watch the video all the way through. I made the mistake of not and tried to pull. But this was a great video and very helpful. Thanks for posting.

[@debbietison5016]

Thanks, I did my 2002 tahoe and your video helped got the job done in 30 minutes.

[@digitalmixer]

Did this fix the air blowing through the vent others windshield

[@dennishelmich1219]

Manny-- Thanks a ton! You saved me a bunch of time locating, removing and installing the actuator. For the top screw, I shortened one leg of a 6 mm Allen wrench and used that as a driver in the 1/4 inch square end of a 12 point 7/32 socket. That combination worked well for me.

[@gregmizell8057]

My 2002 Yukon XL was stuck blowing in defrost, this does fix that problem too. This video is a good one. I did encounter a snag while doing mine. When I removed the old actuator the metal part of the old one stayed on the shaft of the plate that you want to remain in place. I couldn't get the metal piece off without removing the plate. I just lifted out on the white gear enough to pull it out, then I was able to remove the metal part. Now that I had it out I was able to make sure the new actuator would go on easily, and drilling the inside to get the knurls out definitely helps. Putting the plate back in was not too difficult, just awkward and had to pull out the white gear enough to get it back in place. I still completed the job in under and hour and a half. I was able to get to the upper mounting screw with a 1/4 inch drive socket and short 1/4 inch extension and use a 1/4 inch ratchet wit no problem, this eliminates his worst peeve of the job. Without the snag I had, easily a 1/2 hour job. Thanks

[@michaelhuffer9966]

Learn how to make video online before showing us people 😂😂😂😂😅😢😢

[@michaelmcclure8673]

Next time by a Mazda vehicle. Problem fixed.

[@matthewlins6311]

My 2003 Tahoe only blows on defrost! Going to give this a try! Thanks for the video

[@brianradke103]

1/4" drive 7/32 deep well socket on ratchet gets that top screw

[@villamendoza84]

This is a great video you really hit on many issues that I encountered while replacing the one on my truck. Following your tips allowed me to do the whole thing in a little under an hour. The only thing I did do different and it worked for me, for the hidden top screw I used a small extension on a short 7/32 socket.

[@EDOG3408]

did u have a pic of the short socket

[@drfrankenbass]

Thanks for he video. I took the greatest of pains to separate the actuator from the gears without moving them out from the box, but they still fell all apart. Anyone have a good schematic on how they all go back together?

[@matthewl1253]

I know your comment is 5 years old but am pretty sure they can only ho one way but not 100% positive as my defrost and vents are exact opposites now lol, did it once, thought I could do it right 2nd time only to still be the opposite 325k so I don't really care at this point

[@mobildj1]

Recently (2023) my 2002 LS 1500 suburban had the exact failure as yours shown on your video. Your part number you shared is IN Fact, the correct one to get. Look closely to the original OEM ( defect part) .. and notice it has 5 pins total where it connects to the harness!!!…. The Autoparts store did make the mistake to suggest the “correct parts”, to which my surprise, has only 3 pins!?!, ~ it was only after I had already reinstalled the new incorrect actuator & discovered it didn’t work!!! … Wow, I was not happy to go back and clarify their lack of knowledge & they were forced to make this right, luckily I had the original OEM (bad) part to show them what the big difference was: 5 pins vs 3 pins -it does make a huge difference !!! In short, their parts computer was wrong. - this project was 6 hours of pain to deal with. - what a poor design for GM to have on such vehicles, yet they continue it in most current models- enjoyed watching your video, and yes, one has to be creative to make your own tools to get things done- Thanks again!

[@valtierrafamily8176]

Awesome thank u sir!!

[@beninchesapeake]

Good video, thanks. I have no choice, as soon as I unbolted the actuator it all fell down. I will try to install the plastic cam piece first and then the motor. This really is a PITA. On my back, under the dash, and I'm 65 years old but I am going to win. Your video really helps!

[@ShmuelWeintraub]

Thanks Manny, this helps a lot. Typical GM engineering, make repairs as difficult as possible so owners won't want to try it and will pay $900 to have the dealer do it. Hard to imagine this company went bankrupt a few years after building our 'series' of trucks...

[@wcjcnc]

The blend actuator controls the hot and cold. Is this video for the blend actuator or for the actuator that controls where the air comes out of the dash?

[@toddc7916]

Thanks for the video. It is the only one out here. I will try again. Had trouble with the second bolt today. Yea wrenchings going to suck, but if it works it works. I will use your rig. Thanks again.

[@markbelden6919]

Mine broke, took mine apart to confirm, found a broken tooth , while searching online i found a bunch of the ones that don't match, your video helped, 01 suburban 2500

[@robertolsen9742]

Many times there is a gear inside the actuators that is causing the issue. The gear on the shaft seems to split after aging and prevents the rotation past the cracked point. You can rotate the cracked gear 180 degrees or replace it with a new, which I chose to do. I have found the correct gear kit on Amazon for $12.00 (Gear + lube). I have successfully swapped out this gear on the Cold / Heat actuator near the floor in the center of the system and now working on the Blend Door Actuator, I will have spent less than $25.00 and a few hours install time for both. Thanks for the details Manny. your experience here helped me in assisting my repairs.

[@oldschool2722]

✊🏼

[@firemanauxoneknox4287]

much thanks

[@davidwinfield8684]

Great demonstration, thanks a lot.

[@victoriawest884]

Thanks brother. Looking forward to it in the Sub'zs tomorrow 🙄

[@wichjr]

I have a 02 Yukon XL, this actuator was busted, blowing cold air through the defrost vents.. I cheated and only removed the actuator and the black gear plate it mounts on. Then you can move the white gear by hand and it will stick on regular ac vents. I don't defrost anyway so it was a great fix

[@duubtuub3071]

Thank you, Manny, for saying "stupid." I've been up in there twice trying to get at the sumgun out and had to quit because I couldn't see anymore for the rage which welled up against American car "designers". "Those teeth don't do jack." (And they ain't alone...) Thank you for the inspiration of the stubby hex cutoff and wrench. (and the 7/32 mention--saved me starting at 1/2 and working down in a tight space...). I'm wondering if a newer type ratcheting box-end wrench would speed up the top screw processing any. All the best. Subscribed. Hoping to learn more from a man on point.

[@josephmontalbano81]

Good video. I was at a Salvage yard yesterday and pulled out this exact same actuator from a Chevy 2000 Silverado. I don't think the name Chevy or GMC will matter considering they are both the same of General Motors. I'm my actuator today on my GMC truck. Wish me luck.

[@kindredspiritzz66]

this is a nightmare to do. I spent 4 hrs working on mine, best i could get it to do was defrost and defrost/feet. Dumbest design ever

[@1papadeluis]

Man!! I live in Arizona, and we really need cold ac blowing on the front In my 2001 Chevy Suburban only the defroster was working. I was looking for some information everywhere, but nobody was be able to help me. I find your video, found the bad part, fix it and now is working just fine. Thank you for take the time and post this helpful video.

[@clydedent1415]

I changed mines from your video cause you were so destructive great job

[@clydedent1415]

Great video man thanks to you I got the job done I followed your instructions to the t exactly as you explained it....thanks again

[@royalwulff1]

Thanks great vid, and thank you for the trouble you will save me!!! Worked great. Although I had to reset and to do that you have to take ground cable off battery wait 2 min and hook back up and turn key to on position and listen to actuators, they will all reset. It might take 5 min. Problem solved. It does work on 2002 Tahoe

[@billyhall2045]

This is a great information video. Of all the videos I looked at telling me how to replace the actuator ... yours was the ONLY one to give the tip about having to drill out the useless teeth. I'm embarrassed to say I wasted about 1.5 hours trying to get it to fit before drilling. Once I drilled ... voila'

[@palllllllllll]

Thanks Manny huge help also my 1/4 inch drive deep socket worked perfect for the top I think it was a 7/32 1/4 inch drive is small enough to get in there. Thanks again

[@magnumrush]

Thanks for the video. I'm sure this particular actuator is my problem as well. Do you know if the 99 Tahoe is the same as your 2001?

[@timheintich5929]

thank you Manny... part number was spot on. they tried to give me a couple wrong ones at the parts store. Used a deep socket 6mm I believe with a swivel and knuckle for the top bolt with a 1/4 inch nut driver

[@salemcripple]

thanks, I needed to know where this was at. BTW the blend door, and the mode door are two different things. the blend door is what regulates the temperature by mixing hot air from the heater core, with cold air from outside. the mode door is what regulates the the mode (obviously). that is the defrost, dash, or floor vents

[@hm-wm8sw]

hey manny i have the same problem i took out the actuator,i didnt have to much trouble taking it out put i took it out for now ,i manually switched the air to the dash vents till i get the new part thanks for the video .i have a 2002 silverado a bit easier, theres no kick plate

[@trentonroberts2907]

I can see the actuator moving. it will blow a little bit on the floor but none on defrost! it appears to be moving the full distance. any ideas?

[@jesgetme]

Man this video probably saved me so much time. Thanks

[@quietcorona33]

My new hero, thanks a whole heap. Three hour drive home in minus 26 sucked on Boxing Day hope to do this soon. Thanks again.

[@1Chimera300]

I had the opposite problem, i turned the defrost on and it won't go back to dash A/C, hope this fixes it.

[@markbelden6919]

Top screw was a pain, used a 7/32" wobble socket, exact same

[@ramelstevens7726]

hey manny i have a 2004 gmc yukon denali n i have tht problem.. is ther one on each side?

[@NathanInSanAntonio]

Thank you Manny. Very helpful video. Had this exact problem and even had the parts dealer offer the wrong part. So having the part number saved time. The install was awkward but your instructions made it easier. I also had to drill out the part, would have thought I had the wrong part if it weren't for your info.

[@gustmartinez501]

Thank You for the pointers, unfortunately mine has gone out? Will give it my best shot to replace.

[@jamesnails8904]

Very very good video thanks a lot for spending the extra time to make this video its saving me and others a lot of time and money

[@ryanmozisek6464]

Is this part number also compatible with an 03 sierra

[@noelmosqueda766]

Mine is stuck on Defrost also. You think doing this will fix it also?

[@Michael-fm4nx]

Very Good, I bought a 5.5 mm socket and used it the same way you did.

[@victorlopez3853]

I have a chevy tahoe. it's just stared blow hot air in all the vents. could be that it?? thank u

[@davehardy9555]

Excellent video Manny! Thanks for sharing!

[@drewsquickfix]

Thank you.looks complicated.I think im gonna leave mine.lol its stuck on defrost.so I still get heat and a.c. too just slowly. I know what caused this. My vent button occasionally would be between defrost and regular air.I also moved the knob way to fast vs letting it adjust. Im sure it wears out anyway though. I have a 1997 tahoe. I've heard this can cost up to $1000 to fix. Not worth it right now.

[@desert07576]

Dont have to turn car on to move shift lever

[@redhulk111]

They sell the actuator with plate.

[@warrencopeland5341]

The title of the video says," Blend door". WTF

[@royreyna7209]

Thank you for posting this! It helped tremendously. You were right about the time estimation, and you were right about not pulling the gearing out along with the actuator. I should have listened, but fixed it within another 20 minutes. Thanks!

[@stephenstasiak627]

Had to make a wrench that I welded at work to get that screw out

[@imserious2187]

so it's one of these on the driver & passenger side??

[@raula9358]

thanks for the video.. did it, and it fixed the problem

[@EDOG3408]

where did u found the 7/32 socket

[@REHABPOKER]

Ty for the time of making this, helped me a lot. My 2002 was stuck in defrost even when the a/c was on it won't blow out vents just defrost.

[@EDOG3408]

did u fix it

[@dixee6498]

Thank you for taking the time to show us this

[@rohanpaul8133]

great video replaced my driver side actuator according to your instruction went very well took me 45 minutes thanks again

[@rickyace09]

Hello, I have a 2001 z71 and my blows air from the defrost only would this be the actuator to replace?

[@BigSlick1075]

Ricky Davila yes it would be

[@terancecollins609]

Video really helped thanks for posting it

[@salsucas1]

thanks dude it'll save me a headache

[@haroldwallace6890]

Thanks this was very helpful.

[@TheMaximomex]

Great video man, I'm going to try to fix mine next week.

[@angelc7984]

Thank you

[@maple1600]

Thanks!

[@windowreplacementagencywis5122]

Good job.

[@daviddebuhr8995]

Helped. Thanks.

[@imserious2187]

I have a 04, heat blows out every vent except the driver side, is this what I need also??

[@imserious2187]

+koshcon it blows the air out good, it's just cold

[@donniemallett6648]

imserious2187 there are 4 different actuators. the one you need to replace is under the passenger side dash, I believe. You can read other comments on here to confirm

[@imserious2187]

Donnie Mallett problem has been fixed , thanks

[@donniemallett6648]

imserious2187 no problem. Glad you got it resolved.

[@stantok]

Thank you very much for the video it saved me a lot of work. FYI I used a 2 1/2" long 1/4" socket extension with a wobble cut end I purchased as part of a combination socket extension kit. The top bolt came out fast and easy even though I couldn't see what I was doing. I huge thank you for telling us to drill out the splines that saved me endless frustration. Thanks again for the great video!

[@bobirving7500]

Yup, exactly. Stuck on defrost, new part fixed it. 02 Tahoe. Saved me so much time and trouble! Great tips even down to drilling the splines. 👍