Blend Doors and Evaporator Replacement - Part 1, Removal

Part 1 (Removal) of a 3 part series detailing the process to properly rebuild the HVAC system of a 3rd generation (2003-2009) Dodge Ram with a new evaporator core and all 5 air doors without hacking the box apart and taping it back together. All air doors came from Blend Door USA and the evaporator core came from Four Seasons.
www.blenddoorusa.com/
www.4s.com/en/
www.carbonitecummins.com/

[@DanSme1]

John...you're the best. This was a wonderful contribution to the Dodge Truck community! Dodge owes you!

[@travisdillard3223]

Man, I absolutely couldn't thank you enough for making this video! My evaporator crapped out so I'm doing like you and replacing everything. That way I never have to do this again! Many many thanks to you sir!

[@joedirt7602]

This guy should do every single tutorial there is on youtube

[@mrbnasty8090]

Right excellent tutorial

[@88SC]

Just discovered that, if you have an automatic, it might help to put in low before you shut it down, because the selector will be in the way when you move the dash.

[@terryharvey4811]

BEFORE YOU UNHOOK THE BATTERY OR BATTERIES IF DIESEL.ALSO BE SURE TO BLOCK UP THE WHEELS SO TRUCK DOES NOT ROLL AWAY WHEN YOU'RE OUT OF PARK. WOULD ALSO DO THIS IF IT WERE STRAIT SHIFT. .

[@j.walker4739]

Great video. Pulled my dash and changed all the doors in my hvac box, found 2 broken ones. Intake/recirc door was broken completely from hinge and resting on top of blower motor. Thank you sir!

[@MrDeejeroni]

This how-to is beyond perfect. Well thought out and informative.

[@TheJustgrimm]

Very clean and professional instruction. Thank you for taking the time to document and upload the procedures. Beats the heck out of ALLDATA procedure!

[@Duckcomander1988]

thanks bud ur video is the only video on KZbin that shows the 2 bolts above the steering column I was stumped for about 2 hours before I found ur video thanks

[@dannybenson9646]

Best instructional video I have seen on youtube. Now feel confident to do this myself

[@ryan4327]

Very good step-by-step tutorial. One thing I saw in another video is that since there are so many screws, nuts, and bolts to keep track of, it might be helpful to temporarily reinstall them after each component is disconnected, that way you don't have to worry about keeping track of all of them.

[@MrBIG4D]

This is the best instructional video series on the net about how to do this. I'm a 25 year veteran mechanic and this is the RIGHT way to do it. Don't hack your box like the other videos. Two things I would add to this video; 1. To protect your exposed AC parts, take a disposable rubber glove (dust free). Cut a couple of the fingers off and stretch them over your open AC lines. Perfectly sealed and you save your Zilock bags! = ) 2. The video does not state this, and doesn't show this step. On my '06 Cummins had to remove the coolant recovery bottle to get to the left most nut retaining the AC duct work. Two small bolts hold this to the truck. Remove these and move the bottle out of the way and remove the 10mm nut on the left. Then you can remove the HVAC box.

[@vulcanbespock]

Thanks for the info! I have an 06 as well!

[@benmcgovern]

I really appreciate you making this video series. My 08 2500 is blowing cold with a new heater core, evaporator, blend door usa doors, and new actuators all around. By far the most informative video I've seen on any subject. You saved me a ton of time and money! Thank you again!

[@JBselman]

SPOT ON! this series of videos helped me pull the trigger on fixing blend door issues.

[@BigBrotherIsTooBig]

Very informative for those people looking to remove the top dash without breaking it. Some of us don't have cracked and broken dashes yet almost every tutorial out there about removing it involves just breaking it out. Thank you so much flopster843!

[@billybudd9994]

Thanks Buddy, you just saved me several hundred dollars. I had to change out the evaporator in my 2007 Power Wagon. While I had it disassembled I went ahead and changed the heater core as well. Your video saved me a lot of time and money. Much appreciated sir.

[@jburks3185]

All three videos that you made were very informative. Excellent video's. I am fixing to start disassembling my son's 07 to put in a new evaporator core myself. Wasn't sure if I would be able to do it until I watched your videos. With the info you supplied I know I can get it done. Guys like you save guys like me alot of money. Keep up the good work.

[@BearE9090]

Well done video. I was putting this job off for months but after watching your video relieved a lot of unknown stress.I just finished replacing my heater core and repairing the mode 2 door. Thanks for saving me time and money.

[@farmerboyjohn100]

Great video! Thanks for taking the time. You did an excellent job, made it very easy for me. Who would have thought back in the 70's that you could go online and find a video detailing step by step how to do something like this?

[@intl302]

Did this yesterday on my 07.5 2500. There were a couple of bolts on the backside of the firewall behind the passenger battery and relay panel that hid adding a little time to getting the box out (2:45 in your video). That being the only hiccup, and I imagine there will be tiny deviations with model years, you're spot on good sir -- thank you for making this DIY vid! The You make it look easy while I'm over here looking at my hammer and sawzall! Cheers!

[@baumers03]

This video was excellent. It saved me a lot of time and money!! Thanks for taking the time to make such a high quality how to video!

[@michaelbeilsmith794]

Excellent video production and narrative of procedures. Excellent camera angles and simple instructions. You're right up there with Brian of fordtechmakuloco on Fords. Keep up the good work!

[@markbaustian9503]

Thank you Carbonite Cummins and flopster843! I had the mode 1 door and the blend door break in my 2006 Dodge Ram 2500. This was the second time the blend door broke, the first time it was replace by the dealership under warranty. It's a scary thought to remove the entire dash from your truck to make the necessary repairs. Flopster843 shows you everything you need to know from start to finish. To compound things.....my compressor crapped out. I researched the internet (youtube) trying to find the best door to purchase and I settled on Blend Door USA. Sure, they are more expensive then their competition (OEM and aftermarket) but they are built much stronger and this was a task I never wanted to repeat. I also replaced the heater core and evaporator coil while I was in there. In addition, I replaced the accumulator, liquid line, and condenser. Pretty much my entire AC system is brand new. So one Saturday morning I had my son come over to give me a hand. Neither of us are professional mechanics. I had the Freon recovered by a certified technician. All the rest of the work was performed by my son and I. We finished the entire job from start to finish in one day. Blend Door USA is a small company. When I called to order my doors, I was talking directly to the owner of the company. He was very helpful and I even received a 10% veteran's discount. Shipping was fast! Thank you! Special note on this project, you do need some specialty tools to do this job: Ac line disconnect tool, Freon gauge set, and a vacuum pump. A Freon leak detector is advisable to check for leaks afterwards.

[@tiptop3321]

Ecellent Video Flop. Fianally somone postedd a perfect step by step for this. You deserve an award.

[@JohnWilson-wt4vt]

This is one of the most helpful videos I've watched in a long time!! Thank you!!! Very much!!!

[@eb5864]

Thank you for doing this video step by step I would have never tackled this job had it not been for your videos I totally appreciate it keep up the good work thank you

[@brandonrandall3285]

I did the project and followed this video, my truck was a little different but still worked like charm, great video!!!!!!! Best one I found.

[@jamesal-hamadani221]

So helpful brother, I’m working on mine now, flowed your steps, everything went well... keep up the good work

[@troykrebs2840]

Your video's are super detailed and im so thankful you took the time! Im very detail oriented and needed one of the same to give me an idea of what I'm workin with. Thank you again! I know I'm equipped to take this job head on because of you and the time you took to share your experience thoughts and knowledge!

[@elizabethspence6149]

Fantastic video. I really appreciate how well this video was done! I have an '05 automatic. I had a heck of a time getting one of the A/C quick disconnects undone (the one going to the accumulator) I finally cut the line using a compact pipe cutter (I'm replacing the condenser anyway). I also could not get the heater core lines to break free. I moved the clips back and twisted and pulled as best I could, but they would not come free. I finally had to cut them free. I also had an extra metal strap running from behind the glove box down to the front of the AC unit that I had to unscrew. Thanks again for the great video

[@volkmarmaleika1623]

My 2005 2500 Ram Manual 6 speed has a screw in Shifter Extension and also found leaving the heater hoses on at the firewall saved me a lot of time, just pull them through. And then when you reinstall it was better already on. VERY HELP FULL VIDEO.... I just finished my HVAC box with the new BLEND DOOR USA kit.

[@arielelguezabal9750]

Thank you so much for posting this!!! Post more stuff!!! I enjoy watching your videos in general.

[@PimpDaddyNV]

Many thanks for this video. I own a 2004 and I know there's some minor differences but nothing that can't be easily overcome. My HVAC has essentially been inoperative for a few years, due to the blend door problem, only because I was afraid to attempt pulling out the box. This video showed how silly I've been. Thanks a bunch.

[@1969Kakashi]

Hands down the best run-down on this job. Thanks for the info!

[@erics955]

My son and I just did my '07 Ram 2500 last Sunday- took about 8 hrs, used the Blend Door USA kit with all 5 doors and drives. By far, the most difficult task was the a/c lines disconnect! Fought and fought scrappy tools, ended up cutting a piece of zip tie to wrap around pipe and depress clips! Can't thank you enough for the very concise video!!

[@renevillarreal4807]

Those three bolts on each side looked like it had a river… How did you get the rivet out?

[@johnnybigmack1332]

Great video, love how detailed the instructions are:)

[@ushillbillies]

EXCELLENT SIR , I needed a refresh , I did 1 10 years ago , now I've been ask to do another..

[@grasmussenNC]

Excellent vid. i watched this a couple times and had mine torn apart in 1.25 hrs. then I got tot he AC lines......nightmare....5 hours fighting them only to discover a video where the guy cuts some plastic from a paint bucket lid to make a tool to remove the lines. After dremelling and fighting the tool I had bought I cut out some plastic....and it worked. that being said, they have to be finessed out. slide the plastic in, wiggle gently and the line will loosen ad come right out....as easy as we see in the video here. not including the ac line issue this job took me under 4 hours. pretty simple thanks to flopster. the only down side....my top panel was brittle nd all the clips snapped. The replacement costs $307.....I'll be buying a dashmat instead

[@victorflores3272]

I am a girl and I wanna thank you for your step by step directions and demonstrations and explanations that I was able to do on my own...THANK YOU for sharing your God given talent and sharing it with others...GREAT VIDEO and looking forward to pulling you up on next project

[@milesquisenberry4959]

Before I watch this I was worried sick about doing this! This dude made this seem like cake work!

[@ltr6541]

Well.. first nice day in the springtime I guess my truck's coming apart.. I always thought it would have been harder to do than what you just showed:-) awesome video :-)

[@caddy2long]

Thanks for the video. I have to do my megacab while I'm off for the holidays. This helps.

[@cesare3955]

Great video! Very informative. I'm sure glad I found this so I can fix my truck. Awesome!

[@ianmccarthy1323]

Great video. Thank you. Its about 100 degrees here in Minneapolis today and im doing this as a wedding present. Im so out of it im just following your video. Thanks bud@!

[@troy1672]

excellent video!!! If I could give it more than 1 thumbs up I would. Very detailed. This allowed me to know what I was getting into before I got it apart. Thanks for the video.

[@nimbayes]

thaNks a lot I did it and the explanations are just perfect. I'm not an english speaker but the way you speak is very clear you speak slowly and......thankkkkkksssss a lot again

[@victormunoz9936]

I know it's been a while... But This Man, is Very Intelligent.. And knows his limitations. "I'm using my Boss's hair ties" had me laughing for a good while. "Chivalry isn't Dead...just Slightly Wounded." Peace my Brother

[@aeropilot5]

Amazing video! This is very informative. Well done. I have an 07 2500 and will need to do this very thing.

[@oscarrios606]

You are really good at showing this Very EDUCATIONAL AND INFORMATIVE ROCK ON BRO

[@harrisonwebster9189]

Just about to the same to my truck. Nice to see another standard!

[@jeffj144]

Your video is very helpful! thanks for putting this together, it surpasses the others

[@vulcanbespock]

Super job on documentation steps in this video!

[@Iann128]

Thank you for a great video! I had been putting off fixing mine for years. Found 3 of the 5 doors were broken in mine. The Blend Door USA doors rock. I now have full control and air flow back to what it used to be.

[@klaus5686]

Just did this 3/2/24. 2006 5.9 w/ prod. date of 8/05 which makes it pre-2006.5. Couple items to note: there are two nuts on the firewall behind the coolant overflow tank. You don't have to remove the tank to get to them but they are very difficult. To remove the a/c lines, the tool will need to have very thin couplers that slide in behind the pipe or it will not fit. There are different heater cores for pre- 3/2006 and post 3/2006 manufacturing dates. Purchase accordingly. OEM actuators are discontinued. Murrays from O'reillys are the best way to go, because if they malfunction, you can file a labor claim and get a warranty. The blend door USA kit has a different type of fastener than in the video for the actuator that has the rods attached. It now has purple plastic clips like the one on the e-brake.

[@hivmonster]

Doing this on my 06 dually right now. Thank you.

[@cdray1968]

Great video! Thank you for doing this!

[@Rubberthumper]

Thank you for your detailed walkthrough

[@olddirtyburt7522]

Very in depth video. thanks. will be pulling my HVAC out of my 2004 2500 shortly. blend doors and cores

[@okabulish]

Thank you! The best tutorial ever!

[@DIYJeff]

Very informative and super detailed. I love it! I have a question though. I would prefer to not have to evac the system and pull the lines to pull the box out of the vehicle. I'm looking to just replace the blend door for the dual climate control system (even though my Ram 1500 does not have dual climate control) because it's only blowing air on the driver side and not the passenger side. Is it there enough room once it's loose to pull the heater core out, take out the 15 screws from the bottom, and get to the mode door? Or is this just an impossible task?

[@goldrushpro]

I second Leighton Fisher below - "This guy should do every single tutorial there is on youtube!"

[@Naysin2355]

Great job explaining boss, thank you!

[@julianmora7074]

Excellent presentation

[@darwinbyal6021]

Bought the whole kit for the dual temp zones. Great quality. Those of you with the Hemi should know that the engine computer hides the second thru bolt going through the firewall. Additionally mine is a 2008 and it appears that the entire dash is a single piece of plastic. It makes it impossible to do the "hack job" shown on some other videos since you can't remove only pieces of the dash.

[@ChrisWojnarski]

Good video thanks best video I seen so far

[@carlosmosqueda8012]

Excellent video, greetings.

[@pigpoppertx6926]

I completed this over the weekend thanks in part to your video. One note, in a 07 Ram 1500 4.7l there is an electrical panel inside the engine bay (to the left of the accumulator) that conceals one of the screws that holds the HVAC box in place. This electrical panel is mounted on a bracket that isn't easily removed so I had to work in the blind with a 10mm box wrench to get the HVAC box off.

[@flopster843]

That electrical panel is the transmission control module. Since my truck is a manual, I don't have a TCM.

[@josephjones2243]

Pig Popper TX same issue i had I pulled the computer and the bracket just to get it out of the way .lol

[@carlmazziotti221]

Pig Popper TX me 2. I actually snapped the fresh air assembly pulling on the box. Great video but I wish that was specified within the video. I know I shouldn't have used force but hindsight 20/20 rule. It's sitting in the driveway weathering a thunderstorm presently. I'll have to pull that computer panel another day to get her out. Hopefully epoxy will fix the fresh air assembly.

[@cpm2731]

Thanks made this job go quickly. Actually wasn't to bad

[@deepseajesse]

So I'm in the process of completing this job and I need to put my windows up because of rain. I put the negative terminals back and I have no power to the entire truck. Did one of connectors remove power from the truck?

[@marcomorales4637]

Nice video thank you for take your time and teach others …..

[@luisolivares8146]

Excellent job thanks so much for this videos very helpful you know you thinks

[@scottkiddx]

You Sir, know how to make a great video.

[@MrJoemama327]

Great teacher!!!

[@robwinemiller9712]

just curious if you ever had to replace the center actuator in a 2007 ran 1500? you can see if when glove box is removed. do you have to remove the entire dash to get to this? i'm not getting any heat on floor, but up at defrost when in the floor setting. the motor is not moving at all when switching between modes. just wondering. why they would put this in a place you have to remove entire dash. wow

[@terryharvey4811]

OTHERS HAVE ADDRESSED THIS BUT I'M GOING TO REPEAT IT. THE LEFT NUT UNDER THE HOOD { AT 2:43} IS BEHIND THE OVERFLOW BOTTLE. 2 SCREWS TAKE IT LOOSE. ALSO BLOCK YOUR WHEELS AND IF AUTO TRANS PLACE IN LOW RANGE BEFORE BATTERY DISCONNECT. OTHERWISE IT BLOCKS THE DASH REMOVAL. GREAT DESCRIPTION. WISH I HAD SEEN THIS BEFORE THE FIRST ONE I DID. I HAVE INSTALLED SEVERAL OF THE BLEND DOOR USE DOORS AND CAN SAY THEY ARE WITHOUT A DOUBT THE BEST MADE HANDS DOWN. JUST WISHED THEY MADE THEM FOR FORDS.

[@BiggusDickus2]

Thanks for the video flopster......this is on my to do list.

[@johnellis6507]

Yes eeveryone

[@justinschmitz9833]

great job on the video, thx!

[@dodgeram1500tn]

I found its alot easer to take off heater core hoses from pulling the box out from inside and taking hose clamps off, done this a day ago and it was much easer

[@davidanderson3999]

If your lucky, they make several different set up for 06, as Dodge dealer went through 4 different ones, 2 from my truck warranty place, and Dodge ordered 2 different ones to get right one, good luck with that

[@javidcars1274]

Great video. ! Way better than mine lol had to use my phone for recording.

[@jordanmcbain2551]

Awesome video. You should retitle it "Dodge Ram Dash Removal" to reach a broader audience (because I can't find any other videos that detail these steps as well as you do)

[@flash8051]

Wow, THIS is how to do a KZbin tutorial. I put up with my MegaCab "mouse blowing through a straw" A/C for 9 years ('06 2500). He DID say removal of the airbox was..."easy" right? Happy to say my '15 3500 dually MegaCab blows nice and cold. They obviously figured out a better way to divert air to the rear than blocking the front vents!

[@macman216]

if i want to only replace the blend doors do i need to draw down the system

[@xjmathews]

Do I need to do all this if I just want to replace the cracked dashboard?

[@jimwitter9648]

Thanks for the help

[@bangor1952]

Amazingly well done tutorial. Only suggestion is for my 2007.5 Dodge 2500 XLT, there were an additional 2 nuts on the firewall next to the accumulator. Had to remove a small computer on the firewall to access the 2 nuts for removal. Other than that everything was perfect. I there any method to test the HVAC box, ( all the actuators) before fully assembling the dash? I would feel better if I could see all the doors operate before fully assembling the dash.

[@failingdisciple938]

Excellent how-to

[@Cinco_pete]

Very helpful thank you

[@johnwilliams911]

Good one 👍

[@aaronrus]

great tutorial, but i am confused y one thing... why remove the glovebox at all? im pretty sure it only connects to the dash and nothing else

[@user-gq2vn1xj2r]

I'm about to do this - how the heck do you keep track of all the fasteners? Bag and label them? Thanks for the video. This has given the ability to do it myself I think.

[@jmfoshee1]

Great video. Very informative. Do you think the fresh air blend door could be replaced without removing the assembly? My fresh air door is apparently either broken or stuck open. Not bad in summer but cold in the winter. Also, can't switch heat to the floor. (Different door, I know) I feel good about removal and installation of the dash, but I would have to make arrangements to have the Freon pulled out.

[@flopster843]

The recirculation door and the panel/floor door are accessed from the top of the box. You can get to both of them by pulling the dash back and leaving the box in the truck with the A/C system still charged. All of the other doors require the A/C system to be discharged and disconnected so the box can be pulled from the truck.

[@gohstryder23]

Great step by step video. One question? Do I need to remove the hole box just to replace the blend door or can I leave it in and replace the blend doors?

[@flopster843]

It has to come out. The bolts that secure the upper and lower sections together are inaccessible while its in the truck.

[@aletahowell2832]

Awesome tutorial!!! You have given me hope to have cold air, again in my 2006 Ram 2500 diesel. An AC guy told me that the evaporator sensor is bad in my unit because the condenser kick on and off and the intake door is broke, also. He called around and found out that dodge doesn't make the evaporator anymore! I can't find an aftermarket part either. So, I'm wandering if I buy a new evaporator, will it have the evaporator sensor with it? AC guy was going to charge $1K to pull the box and replace the intake door and still couldn't replace the sensor! He suggested I go to a junk yard and try to find one. I notice you didn't mention replacing the evaporator sensor so, I'm hopeful that you can give me some advice as to what to do! After watching this video, I think I could do the work if I can get a solution for the evap sensor. Please help!

[@kylewetherington]

In my 2002 I had to remove the pcb board to access an HVAC housing nut for a total of 3 nuts on the engine bay side.

[@jasonball2728]

Thank you!

[@prestonatkins1875]

I have a question? With everything you have covered, does it dissable the airbags?

[@flopster843]

Airbags are temporarily disabled when the batteries are disabled after the capacitors are discharged. Everything is recharged and operational after they're hooked back up.

[@mikestill5819]

Thank you for this , I need to do this to my 2005, and I've deceided to trade it in or hope it is totalled in an accident.

[@kreutzer81]

I can’t get the 3/4 ac line off to save my life. I have tried two types of tools, including what is used in the video. Any suggestions? I’m about ready to just give up and live with no defrost or a/c at this point.

[@flopster843]

Try to put some penetrating oil in the spring-lock fitting. Try to twist the line around to make sure it's not stuck. Lots of push-pull motions while using the spring-lock tool. If all else fails, cut it off and replace the line. I've had to cut a few off because of corrosion in the connections.

[@hunkereddownoutdoors]

Will this be similar to a 2004?

[@petedamron]

have a 2005 Ram 1500. replaced all the blend doors. used your video... I used Dorman blend doors. did not replace any actuators. my Defrost/dash vents all seem to be working. How ever when you turn key on I can hear a motor opening and closing non stop. when you turn key off it stays on for approximately 30 sec. Any ideas?

[@flopster843]

You'll need to look up under the dash and figure out what is doing what before you can troubleshoot the problem. When a motor continues to turn, that's usually an indication that the driver has stripped out the teeth in the door. Watch the drivers and see which one isn't stopping properly to isolate your problem.