2004 dodge ram 2500 hvac mode 1, mode 2, blend door using heatertreater kit

This is my installation of the Mode 1, Mode 2, and Blend doors on a 2004 Dodge Ram 2500 ST. I purchased the upgraded doors from HeaterTreater, pulled it all apart and installed them without too much trouble.
If your HVAC doors aren't working, the kits from Heatertreater is good. You need some tools, like a dremel and a drill, but with even some basic skills anyone can do this.

[@ACE-le8oh]

I heard folks say to do it the right way...well doing it this way is easier then having to disconnect battery along with other connectors around the front dash along with steering wheel with air bags and the one Infront of passenger side. But doing the work like this is great and cheaper since shops charge way too much an some do it just like this and still charge you high dollar for letting them work on your vehicle. Great job👍🏼

[@tomrepici9608]

I had the pleasure of installing them on my old 2006. Those doors are very well engineered and constructed. And their instructions were 100% on point. Your vid was great for installation - I am planning on doing my doors on my 2004.5.

[@jonpino3810]

this was soooo...helpful man and I thank you much o grande..

[@seanpam6967]

Watched your video and changed both doors in mine. Thank you very much! It saved me a pile of money!

[@sideshowbilly3755]

Thanks for posting this. Very informative. I have a 2003 Ram with a broken blender door (not the actuator). Other videos on KZbin are incorrectly confusing the blend door with the recirculator door. Thanks again for providing this.

[@malbor]

+Bill Walters Prior to me doing this job, I watched all the videos on the subject and read a lot of forum posts on the subject and all of it left me with some unanswered questions...so I made this video. I'm glad you found it useful. I generally like to make videos on how-to when there isn't a whole lot of info out there.

[@seniorjuanvaldez]

+Bill Walters please don't do this, take the time to do this job right or pay to have it done you'll be glad you did

[@RudyRivera60]

this video was better and more helpful than all the other vids on KZbin about this problem thanks man

[@1204timyr]

Love the video man, thanks for sharing!

[@RudyRivera60]

awesome video man was kind of scared of the cutting part but ure video deffinetley helps alot looks like I'll be ordering these heater treaters doors, when I put it on my front vents it keeps kicking it out the floor vents, the driver side front vents blow hard the passenger side blow low and comes out the floor vents

[@MrTurbo565]

Good video. There is no telling how long it would take to pull the entire plenum out. I don't have that kind of time myself.

[@howardtoob]

Good write up. I am getting ready to do mine. I have to admit I am a little obsessive and was very inclined to take out the dash and, "do it right". Truth be known, this way makes more sense and cents. I know it goes against my better judgement to cut into the plenum but my, "better judgement" has been a PIA anyway :). This will all be hidden and function just as well as prior to the destruction. BTW-It is Dodge that should have, "done it right" in the first place.

[@malbor]

+howardtoob I went back and forth about it as well. If the truck were newer, I probably would pull the dash. I'm glad I did it this way, it saved a lot of time and I didn't have to mess with the AC and coolant. It works just fine and there is no visible indication that anything is any different. Good luck.

[@TejasToolMan]

so tired of cold feet in the winter guess i will be cutting away this weekend

[@noahupham1243]

I got a problem with mine the a.c only blows out the driver side so it's the inner door closest to the fire wall correct?

[@hey_youtubeim_back2159]

Do you know if a 2006 HVAC (heater box) module will fit my 2003? Both being dual zone of course.

[@ScottDLR]

Just realized that the 03 dash looks identical except it has 5 dash vents - one in the middle and two in front of the passenger where the 04 has one in front of the pass. Wonder if they changed it because of lousy flow.

[@MidnightPolaris800]

What are you talking about? I have a 03 and a 05 and they're both the same

[@ureasmith3049]

Thanks for the info. Dang! did'nt realize had to do such a hack job to fix that.

[@imjabroni1]

+UreaSmith It's not the only way. You could pull the entire steering column and dashboard off, drain and disconnect your heater core and/or AC evaporator, pull the plenum out and replace the doors nicely on your workbench. Reassemble.

[@ureasmith3049]

***** Yeah, might wait till spring and do it the right way.

[@malbor]

Five and a half years later, and I have not had the slightest problem with this fix.

[@joeymaynes3287]

What kind of tape did you use that wont fall off with the heater

[@malbor]

@@joeymaynes3287 HVAC Aluminum foil duct tape. The kit from heater treater included it. You can also buy it at any big box store and probably most hardware stores.

[@joeymaynes3287]

Thanks my truck the door seems jammed not broken my dash was in peaces when i bought the truck i think pieces may have fallen down the vent and jammed it when I twist the white piece that the Actuator motor goes into it hardly moves like it's stuck

[@malbor]

@@joeymaynes3287 Pull the white things off, you have to really yank them with pliers or small vice grips. There is a pin on them. If the pin still exists, the problem is the door. If the pin is gone, you should replace both bits. If your doors were jammed, more than likely the pins are sheared off. While a lot of people have complained about this particular repair, it works just fine. If I pulled the dash off this old truck, not only is it a much bigger job, I suspect it wouldn't go back together right and would probably rattle. Shrug. I still have the truck, if you look at my other videos, I just replaced the control arms a couple months back.

[@joeymaynes3287]

Agreed thanks for the help I will let you know how it goes

[@kevinwhetzel3036]

I know this is an older video, but would you happen to know what the part# wouldve been for the 2 door kits. That was below the radio. Or was they both the same? Having difficulty trying to get these. Thanks

[@malbor]

Hi, the parts are still available. heatertreater.net/dodge-ram-02-08 The area below the radio uses the mode1 and mode2 doors. I have no connection to that company but the hvac was still fine when I sold the truck last year.

[@williamdiaz5981]

you saved me the hassle of taking the whole dash out by my self. god looking out:)

[@walter.s8145]

Best blend door install that I have seen.what kind of tape is that you used to patch up the cut outs.?

[@malbor]

HVAC Aluminum foil duct tape. The kit from heater treater included it. You can also buy it at any big box store and probably most hardware stores.

[@frankthomas2052]

I have a 03 ram and it's stuck on just the vents accessories and heat both work good just stuck blowing out the vent and nowhere else you think this could be my problem to

[@malbor]

Yes, that's exactly what my problem was. Only blew out the vents. You probably need to replace the same doors I did here. Mode 1, Mode 2 and Blend. 2002 through 2008 all had this same issue.

[@jenandryanwells6289]

Can I keep the section I cut out and just use glue or epoxy and place it back to cover the box when the new doors are installed instead of using the tape?

[@malbor]

Jen and Ryan Wells if you buy the doors, you get the tape. I'm not sure how well it would work with glue. The tape has held for 30 months now, no reason not to use it.

[@mrmiked6577]

I get no air to defrost at all, but everything else seems to be working. The Heater Treater guy said it's almost definitely the Mode 2 door. Watching your video, I wonder if it's worth to just do both of them, since it's being cut open anyway....? Has anyone had this problem fixed "the right way" (no cutting - full dash pull) by a professional? Wondering what they charged you...

[@malbor]

Mike D I figured I was in there, may as well fix the three. I don't care about recirc. It's a long job to pull the dash, ac and heater core to get the plenum out, so it's all labor.

[@007jhagga]

full dash about 7 to 8 hours of work i guess....close to $1,000 plus parts, about $1,300 , had a friend take his to dealer ,

[@SuperSkaterwilly]

Would this help if I only get hot air coming in when I have the ac turned on no cold air comes out

[@malbor]

This only helps if you turn the dial for defrost (for example) and it stays at the floor or vice versa. It could also be the blend door(hot/cold mix), but if you don't feel cold mixed in it's probably the AC system. If you can feel it getting colder when you push the AC button, your AC is probably working and then replacing the blend door would help.

[@ashleyclark7613]

What's the symptoms to what you fixed? I have a 2003 3500, and it blows AC and heat with plenty of pressure, but it won't switch to defrost or feet, it is stuck on blasting air in your face. This looks like a nightmare.

[@malbor]

+Ashley Clark The issue for me was that it blew out the vents at you....fine for summer but couldn't defrost. It's not really that hard. A few hours work.

[@dodger4401966]

I have a 2004 dodge ram. the a/c blows great only thru the front vents.i have no heat blowing anywhere.do you know what door allows heat into the vents thanks

[@malbor]

+david fries The Blend door(s). That's the door I replaced at around 5:45 in my video. There are two doors that will flop closed to allow AC air to bypass the heater core. The main blend door is probably broken but the follower door which is attached with a little rod, probably isn't broken. Also your mode 1 and mode 2 doors are also probably broken. You pretty much need to do exactly what I did in this video.

[@dodger4401966]

+malbor thanks for your help. ill give it a shot tomorrow

[@tracyhill5647]

I have a 2009 Dodge Ram I cannot get no power to three of my blend door Motors wondering what the problem is at will it will change from blowing on the floor to defrost hers but the tank temperature control does not change and I have checked all of the blender motors and they all work out of the truck hooked up to a battery charger but in the truck they will not work at all

[@malbor]

Sounds like a fuse problem to me assuming the doors aren't broken.

[@007jhagga]

Your main control module is most likely not good ..the one where you have 3 control knobs in the front dash,, that is asmall computer that controls all the doors, is about $120 at auto zone EXCHANGE . remove screw thats behind the small hook near the passengers knee,and screw on bottom on under the panel by drivers knee, then pop open the center part of dash,take old one to any parts store and get new one. easy job.

[@ty6896]

I’m having problems getting hot air to flow. So looks like I need to do this sooner or later. Did you put the pieces you cut out back in place or just discard them and tape over everything??

[@malbor]

I taped the original pieces back in. If you follow the heater treater kit instructions, it leaves some decently strong attachment points. For the record, I sold this truck back in June. The flaps and the HVAC were still working fine after 6 years. I know some people consider it a hack job, and it is. That said, not having to evacuate the AC and having a dash that doesn't rattle because it's not been out was worth it to me for this.

[@ty6896]

@@malbor I’m sure you can take your time a bit and cut it more cleanly??

[@malbor]

@@ty6896 Probably. I used a dremel. Shrug. It was a utility truck for me, but in the end, it really didn't make any difference how it was cut. I cut it, replaced the flaps, taped it back up and it was rock solid for 6 or so years.

[@gmoney8919]

Any ideas how to do the lower blend door also? Mine seems to have broken off? What does that one even control?

[@malbor]

There are 4 HVAC doors in this truck. This video includes 3 of them. It does not include the outside air/recirc door. I'm not sure what door you're referring to.

[@gmoney8919]

@@malbor there is actually 5. The blend door you did by next to the recirulation door also has a lower one. It sucks I ended up have to cut metal bracket. I wish I would have just taken plenum box out with how much time it took me.

[@jean-lucmelleker8206]

Hi, I'm writing from Brussels (Belgium). I'm really impressed with your video. I have a 2004 Dodge Ram with the same problem...always cold air on the floor on the driver's side.whatever the position of the control switch (floor or defrost). I guess I have to replace the mode 1 + mode 2 doors.... Once you've cut the plastic pieces, what do U use to refix them ? Is it a special aluminium tape used for this purpose ? Thanks a lot. Jean-Luc PS: sorry for my bad english

[@malbor]

Hi, it sounds like you had the same problem I did. I'm of the opinion that you may as well replace the blend door while you're in there as well, but it definitely sounds like you need the mode 1 and mode 2 doors. If you buy the doors from Heater Treater, it comes with the aluminum ducting tape. You can also buy the tape anywhere that sells things for fixing heating ducts. It's not the same as "duct tape" as that is a fabric tape. This is an aluminum sticky tape and it works very well. I did this fix in June 2015 and it's still working great in March 2017, no problems at all. Good luck.

[@jean-lucmelleker8206]

Thank's a lot. Il will order the doors a-t-il Heater Treater, these are aluminium ones I think. Best regards

[@Pnut-77547]

+malbor hello, sorry to bother you. my 04 dodge ram 1500 blows warm air for 5 seconds and goes to cold air after. i have never had heat in this vehicle and now i cannot see out of my windshield. i checked my heater core hoses and both hoses are hot . is problem inside door? thanks for taking time to reply. great video!

[@GarnettM]

That`s my problem which one did you figure was the floor vent ?

[@malbor]

It's probably your mode 2 door. If you're going to cut into the box, do both the mode 1 and mode 2 at the same time. For what it's worth, I did this repair 4.5 years ago, and have had zero issues with it. Still works just fine.

[@GarnettM]

@@malbor Thanks I'll look into it even if I have to prop the lower flap open some

[@skip62000]

This is great but my lower and upper dash are not able to separate as this demonstrates. The upper dash contains the airbag and the entire assembly must be removed to access the motors/actuators. NEVER AGAIN A DODGE.1st time it broke was under warranty and now its on me. I just wish it was this easy.

[@ijosh61234]

Why did you cut the metal bracket?

[@malbor]

Unless you pull the dash and plenum, which includes removing the refrigerant from the AC system and draining the heater core, there is no other way to get to the lower motor as it is nearly flush to the bracket. Not to mention, once the bracket is out of the way,. you have easy access to all the plastic that needs cut. It's been over two years since I did this repair and everything is still good, works great and there are no rattles or other issues. Perhaps someone with much smaller hands and a lot more patience could work with that bracket in place, but it would be very difficult.

[@lukechuk8912]

good video man, overall how long did that take you?

[@malbor]

All in, it was about 3 hours.

[@terrywaters6186]

@@malbor Took me that long just to get all the screws out today and expose everything. Kit is in the mail on the way to me. I hope the instructions are good because I see no way to remove the actuator in order to replace the door behind the glove box whatever that one is called.

[@malbor]

If you're talking about the blend door, you'll need a long screwdriver. The motor was up and to the left of where the glove box sits. I did not replace the recirculation/Fresh door, so I don't know what that part might involve.

[@007jhagga]

@@terrywaters6186 The door behind the glove box and above the blower motor is called recirculating door, it lets outside air in , mine broke so I order a new one from amazon and put in there ,just made a small bracket to hold in there completely closed, dont have outside air any more, but sure helps with the a/c during the summer here in Texas.

[@jeremykamel9655]

I dreaded taking my dash out for years. But I needed to replace my AC evaporator in the heater box. Note to everyone. Taking the dash out is way easier then you think. I’m not saying it simple. But if you get your heater treater doors and follow the blend door USA video for taking apart the air box then you’ll be fine. I’d never cut my air box up like that. EVER. This guy is doing well enough but there is no way I’d recommend this. I’m a journeyman diesel mechanic and this process is a hack job pure and simple. I’d fire someone if they did this. And I’d sue a shop if I took my truck in and they did this to it. Again this guy is following the instructions properly I think but my god no no hell no. As I wore this my dash is taken apart and I just finished installing all new blend and recirc doors and foam. It’ll be going back together tomorrow. It’s a weekend job of done at home. Pro tip. Take your truck in and have an HVAC shop evacuate the Freon and disconnect and plug the ax system. Then get a new evap coil and heater core. Just replace them while you’re there. Along with the upper and lower heater hoses because it’s easier to cut them off. Then get a roll of open cell 1/2”x1/2” window/door foam. Have an 8mm through 18mm sockets and wrenches, needle nose and regular pliers. Remove the drivers seat. It’s 4 bolts and 2 wires. You won’t regret it. Beside you can really vacuum your truck out then. Search KZbin for dash removal of your year make and model. “2006 Dodge Ram 2500 dash removal” or “2006 Dodge Ram 2500 Heater core removal” then “2006 Dodge Ram 2500 Blend Doors” Do it right. You won’t regret it.

[@themattofalltradez]

The average mechanic can pull the entire dash out of these trucks in about an hour, they really are not that difficult. I agree with you, do the job the right way! I used Blend Door USA (paid $320 for their doors) and very satisfied.

[@gregs9381]

Malbor , sorry for the uncalled for remarks , hey i do this stuff for a living and i get thrown into these issues all the time , g

[@malbor]

+greg s No worries. I figured your comment was tongue in cheek. I've been working on cars and building engines since that late 70s. I've pulled apart enough dashes that if I never do one again, (and I won't), I'll be a happy man. Nothing worse than missing clip or you get it together and now you have a new rattle.

[@seniorjuanvaldez]

why would you destroy a 300 dollar plenum?

[@malbor]

+Terry Vicena Destroyed? It works perfectly. It doesn't leak air and it is better than it was from the factory since the doors will never fail again. How is that destroyed?

[@Badcode0101]

WTF dude...did you kill it???

[@malbor]

Naw, still working fine after 18 month or so.

[@gregs9381]

Your a hack , remove the steering etc. and pull the dash, takes 9 hours and it is perfect when your done , put in new cores and make nice , you sleep good at night ,g

[@malbor]

+greg s You forgot that you have to drain the cooling system, probably replace the heater hoses, then you have to evacuate the Air conditioning refrigerant into an environmentally safe container. Then you remove the AC core and hope the lines don't get damaged. Once you replace the stupid flaps, you re-assemble it all, refill and burp the coolant system properly, then re-charge the AC system and do at least a 30 minute draw-down leak test. So I guess to start off, you need to go and get your Air conditioning certifications from the government before you even touch a single bolt. Hey man, it's worth it for an 11 year old truck, only the best.

[@moncorp1]

+malbor ~ yeah, people that act like yanking the dash and the housing crap is the way to go. Weekend warriors aren't going to have the means to fool with that nonsense.

[@TejasToolMan]

damm right!

[@terrywaters6186]

Nine hours of work every time one of those poorly designed OEM doors fail? No thanks.