Blend Doors and Evaporator Replacement - Part 3, Reinstall

Part 3 (Reinstall) 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/

[@robertpapp96]

You are amazing. These 3 parts were the best instructions for this job. Clear and informative. Appreciate for the upload.

[@ramcnei0611]

Hell yeah man! This was by the far the best video for the DIYer. Thanks a ton for taking the time to do a quality walk through!

[@mjspinosa]

just did it- awesome video- there were a few differences in my '06 but I got around them. I would recommend keeping the hoses attached to your heater core- easier than trying to get them out in the engine bay- also attach them to your heater core before you reinstall the hvac box- they will fit through the firewall hole. Also its always a good idea to make sure your AC springlocks will lock onto the AC coil if you are replacing the coil- prior to closing up the dash- some parts are slightly different- my new coil didn't work so I had to pull the dash again and put the old coil back in. thanks for making such a great video

[@Engloid]

I did this job a few weeks ago, and this video was the reason I decided to do it myself, as well as the reason the job went smoothly. The only thing I messed up is I let the steering wheel spin while I had it out. I didn't break the clock spring, but it was one turn off, so I had EPS and another light on the dash. To fix it, I had to hook up a scanner so I could view the steering angle. That allowed me to know which direction to turn it to get it back to zero. I then pulled the column again, and reset the steering angle sensor. My heat and air works better than it has in the time I've owned the truck. I highly recommend Blend Door USA for the parts. Thanks!!

[@davidbormet5485]

This was awesome! Very well done and made simple for us first timers. Thank you Sir!!!

[@landlord5569]

GREAT work sir. Your video shooting skills are noticed...you've made a difficult job very easy. Great step by step tutorial. This should be linked to cumminsforum

[@volkmarmaleika1623]

I just did mine with the BLEND DOOR USA kit... But I got to tell you my 05 2500 has a metal strap that hung from the dash to the bottom of the HVAC box. Got it done THANKS

[@kenneystech]

hey thanks for the info and quick response also thanks to the guy at blend door usa shipped my kit same day and also helped with tech support . for you mega cab guys cut some holes in the air diverter screen to increase air flow to panel vents . there was no need to remove or even unplug the factory infinity amp

[@ryan4327]

One of the better videos on this. Soon enough I'll be replacing the doors, evaporator, and heater core, something I've been putting off because it's such a pain. These videos make it look doable, though. Thanks! Update:. So I did this in my 2003 Ram 2500 5.7L, took me about 8 hours by myself taking my time and being very careful. I noticed that many plastic and rubber components had become brittle so there was potential for breakage. Having a decent 1/4" battery driver really helps. My truck was close enough to what was in this video that I was able to figure out any differences. So thanks for this, it really helped!

[@k1y2l3e0]

Your videos Rock just did my 2004 Dodge Ram 3500 yesterday with the Blend Door USA units, makes something that seems so hard, easy, took me 7 hours total out and back in in one day THANKS ALOT!!!!!!!!!

[@lizrivas8576]

Thank you for posting the reinstall. Made it so much faster than trying to work it out with the first video in reverse! Overall a great 3 part series to follow along.

[@chrisbgarrett]

Thank you man! Gonna buy all the parts and do it during Christmas break. Thanks

[@pullordienow8392]

thanks man, you've been my buddy the last two days.. job done and working great.. took me three hours to get the old AC lines apart.. but hey! saved me 800 bucks or more... thank you!

[@ShainAndrews]

Seriously detailed series. Really nice work there.

[@johnbowes8946]

One of the best videos on repairs. Thank you

[@johnnfanning2680]

Man what great videos. You explain everything so clearly. I did a 2006 Dodge Ram 2500 couple small things were different but nothing I couldn't handle. You save me a ton of money. You are much appreciated thank you. Now I have heat and AC all thanks to you

[@Zerkini]

3 parts, separated into logical sections of information. By far the best method, hands down the clearest instructions. This type of precise information is exactly what I was hoping to find to do this to my dodge ram. Simply removing parts until you dig your way down to the HVAC will only result in useless removal of parts, hundreds of screws, and a headache once you realize you could have removed the entire dash all at once. I have no idea how this hasn't had many more views. I've added your 3 part instructional video to a playlist as this is in my near future due to a recirculation door issue.

[@dsim3211]

I was able to do this job myself because of these great vids! Thank you so much!!

[@danielsmith2447]

You are a great teacher, you don't know how angry I am at myself for not discovering this video before I spent hours disassembling the dash only to see I should have done it the way you described. Thank you for a top notch tutorial.

[@Jose87694]

Thank you for these great videos. I have an 03' Ram 1500 and I am doing most of the steps to replace the recirculation door. Lot of bolts and nuts but I am almost done. I did not have to pull the whole black box out for this. It was really helpful to know what and where are all the bolts that we have to deal with before going into the mission. Keep up the good work!

[@bobbyboykin7137]

Dude I know you posted this years ago, but you have no idea how much hassle this video saves people. Seriously. Thanks a million. Do you remember what size/dimensions that insulation was you used to replace the rotting foam?

[@TheMoysworld]

This is a very good series of vids however having just completed this the only thing I would change is to stop at the part where you set the dash in place with one bolt per side and with steering in place and every connector plugged in do an operational check on the blend doors before moving on

[@toddtalladay7265]

So great set of video's, they were extremely helpful. Couple comments - for people like me that have never used a A/C disconnect tool need to add that to use the tool you need to push in the tool toward the "fat Ring" while pushing the "fat ring" towards the tool. There is a spring inside that ring that the tool needs to compress. I ended up using a pair of pliers and gently squeezing the two together then was able to get the a/c line out. I went one step further and removed the accumulator to make more room. That being said you would need to cap those lines and replace those orings as well. also i have a 2006 3500 and i had two more nuts behind the reservoir i had to remove to get the heater box out there was also a metal strip behind the glove box that was bolted to the dash on one end and the frame behind the dash on the other end. had to unbolt that as well.

[@onnielgarcia183]

Thank you so much for taking the time and knowledge to share with us with the same problem with this trucks your 3 videos they have been the most complete and best explained that I could find on KZbin thanks ones again

[@lucascoulton]

Excellently done videos! Now I know exactly what to do before I even start.

[@joetterolison4093]

Your videos answered more questions I never knew I had about the Dashboard Thanks for Great presentations Ken Florida

[@intl302]

7.5 hours for this amateur! Blows hard and clean, now to see if it holds a charge! Thanks for the how-to. I'd venture to say this saves the user upwards of $1k in labor charges.

[@pryvisee]

Easily. Got quoted for 1050$ at the stealership.

[@donisenhart4123]

Best to the point video series. excellent. Thank you.

[@garys2787]

Great vídeos. I did a search on KZbin a couple of years back on this but your video did not pop up for some reason. Perhaps because I searched it by typing "Dodge Ram" on my search. Perhaps having "Dodge Ram" on the name of the videos might be helpful to other searching this subject. Just a humble suggestion. Thanks again for taking the time to make these helpful videos. 🙏🏻

[@georgecolbert3247]

This is the best remove, repair, and install video for the 02-08 Ram heater box. Nice job! I think the work time estimate is a bit optimistic though for the first time its done.

[@amandadavis9726]

Should be able to cut your time in half, the next time you have to repair it. It’s kinda like replacing the transmission throttle control actuator,…do it once, and you’ll know exactly what it takes to remove and replace.

[@titomia1]

Outstanding video, very detailed. 10+

[@andrereid2238]

Thank you for this video. Very helpful

[@Engloid]

Great video. I was planning on paying somebody to do the job, but after seeing this, I'm considering doing it myself on a Saturday...if I can get a warm one.

[@x12390]

most detailed instructions so far. when you accessed blend door #1 from top I hoped #2 would be the same, since that's my problem, but no. top access would mean I wouldn't need to remove hvac unit. oh well.

[@ChanceDeTexas]

thanks I just ordered my blend doors!

[@jamesal-hamadani221]

hats off! Keep up the fire..

[@tylercasey1951]

Great videos and thank you. Would these videos relate to a second gen ram also?

[@jimu57]

Great video. I have a 2002 RAM 1500 that I am attempted the same thing this weekend.

[@flopster843]

The only hard part is getting those stupid spring-lock connectors on the AC lines apart. Other than that, it's just nuts and screws. Make sure you cycle the doors by hand in the box to make sure yours don't bind. HVAC boxes in early trucks are sometimes a little off square.

[@jimu57]

flopster843 Well I had great success. I had a little trouble with a/c lines but I made it thru it. I ended up rebuilding the entire heater box. I have good air flow now. The only issue that I cannot resolve is that the airbag light stays on. I wonder if I left something loose in the dash. I did disconnect the battery again to reset everything but the light is still on. I am trying to troubleshoot still. Andysuggestions about this issue you may have will be greatly appreciated. Thanks again for a great video!! You saved my a lot of money.

[@flopster843]

You might have something loose behind the dash, or it could just be a stored code from the airbag system. See if you can get the code cleared with a scanner before you tear the dash back apart.

[@jimu57]

flopster843 there was not a code set for the airbag which is odd if the dash light is on. Any suggestions?

[@MrDwaynePoff]

Watched all 3 videos... thanks for making it look so damn easy! Lol Any idea what I should start taking out if I have heat on passenger side and cold air on the driver side?

[@MrJoemama327]

One of the best video to date. I like the way you said how many bolts there were in every process.You explained everything in great detail. I'm having a problem with my 2002 Dodge Dakota no heat in the cab. Heater core is clean, flushed system new thermostat, new ant- freeze and new Motor. I think it may be within the heater box. Do you have any videos on my truck. It would help out a lot or do you have any insight on my problem.

[@flopster843]

I have not personally been into the dash of a Dakota, so I don't have any instructional videos. If the coolant is flowing through the heater core properly but you still have no heat, I would suspect a broken blend door(s). You can pull the glove box and look at the main heater box to see if you can visually verify that the actuators are moving properly. If there's no movement, then you probably have a bad actuator. If there's movement with no change in heat, you probably have a broken blend door. Most Dodge trucks have a similar structure, so I would suspect that the Dakota would be similar to the Ram. Take it slow and double/triple check all of the points around the dash and you can get it all taken apart to diagnose. Blend Door USA will do custom doors for any vehicle if you want to get a set for your truck. It would require that you send them the broken pieces and wait a couple of weeks, but they'll do it for you.

[@valentinoreyes6641]

Awesome video... I want to know where your shop is and have you do mine... let me know what part of the USA 🇺🇸 your at

[@jamestoole3614]

Is there a system you use to keep all of the nuts and bolts organized so you know exactly which ones go where during reinstallation?

[@lowriderssux]

Do you know the size or the mopar part numbers for the o rings need? & quanity for both lines? Thank you!

[@libertyforamericanow]

My upper dash cover was brittle. Broke it.

[@abelcerrillo2162]

u can also check the a/c vaccum lines sum can be disconnected or they can brake an cause the flap door not to open...

[@flopster843]

There are no vacuum lines in this system. All actuators are electronic.

[@marktra8two]

Great vids man, just got done doing with my 08 ram 1500 4.7. However, after getting it all back together my airbag light is on now. I made 100% sure no wires got pinched or snagged. I've triple checked everything. I've checked the fuses, checked for lose connections or pinched wires. Everything looks normal. Any ideas

[@flopster843]

You have to have missed something small somewhere. Try disconnecting the batteries for a few hours to reset the computer. If that doesn't work, pull the abs codes and see what is faulting.

[@kenneystech]

i have a 2006 dodge 2500 i purchased the blend door usa parts and getting ready to do the job . my truck has the infinity stereo do i have to remove the factory amp to remove the dash . dodge charges a extra hour if a truck has the factory amp but wouldnt tell me why

[@flopster843]

Dealership instructions have them disassemble the entire dash to get it out, which is probably where the extra hour is. I have not messed with the factory amp, but I believe the process shouldn't change much. You might have a few exta electrical connectors to remove. Just go slow and look for anything different.

[@Tahoebronco]

Are these steps pretty much the same for a 4th gen 2011 Dodge RAM 2500?

[@willieguapo]

I have same interior on my 2006 diesel. I hear air rushing under my dash when ever I'm on Boost. Do you know if theres some kind of Air hose that comes into the driver compartment under the dash. I imagine it's broken

[@flopster843]

There are no air hoses running into the dash on the Ram trucks. It sounds to me like you've got a torn boot on one of your charge pipes. The one going into the intercooler on the turbo side seems to be pretty common.

[@willieguapo]

Sweet. Thanks for the response. I'll check it out tomorrow

[@2107ATL]

Do you know the part # for the new AC line seals and what oil do you recommend to use on them after installing them?

[@flopster843]

Just go get a universal AC O-ring kit from the parts store. Cover them with PAG46 oil when installing.

[@2107ATL]

Sounds good. Thank You!

[@willieguapo]

KZbin University Certified!!!

[@tajhealthnature8570]

Nice save alot of 💰

[@jguillermozopillactle5601]

How can i order those doors?

[@videoman4424]

how did you remove the upper trim panel without breaking the tabs?

[@flopster843]

A thin plastic wedge and being very careful. Push right up against the locking tabs.

[@thekidd8179]

after doing this my airbag light is on what can it be?

[@alexrmz4728]

Hey any ideas on whytruck wount start after I put dash back together??

[@alexrmz4728]

I found a couple extra plugs I don't remember unplugging under driver side

[@alexrmz4728]

Nevermind I figured it out, thanks

[@petedamron]

I lost the thread on your answer? 2005 Dodge ram pulled dash back out looked at all the actuators and shafts everything is fine. of course with the dash out the wiring harness is disconnected but I did test each actuator and they do successfully closed and turn off and then by reversing open and turn off period what I was hearing before I took my Dash back out is when I turn my key on I hear electric motor like a gearbox wined up and stop and then lined up and come back on it just continuously does this. and when you turn the key off it turns on and off making that noise for up to a minute before it finally stops. I've got the dash out on the saw horses I don't see anything electronic that could be causing this. any ideas what that noise might be.

[@flopster843]

I'm not sure what could be making that noise. The HVAC box is the only thing under the dash that has electric motors on it. The only thing that I can think of that would make noise like that would be the fuel pump, but you wouldn't hear that from under the dash.

[@petedamron]

flopster843 Your not going to be leave this. I can kick my Butt. I replaced the intire interior from headliner to complete Dash because of smoke Damage. I replaced factory Radio with refurbished Raidio. unbelievable. It was the CD player. I took Dash completely back out. Sound was traveling I guess. Thank You laugh too Hard....

[@matthewbayles2116]

Perfect video. How well are you at internet troubleshooting?

[@flopster843]

It's difficult to troubleshoot any AC problems remotely. I could maybe give you some areas to check though. What's the problem?

[@matthewbayles2116]

flopster843 so my AC only blows okay on the driver side on high, the passenger side by the radio faintly blows, and passenger side by the door nothing. While the AC is on air is coming out of the dash vents, and the Floor vents are also blowing. I have it on the recirculating dash setting, not floor and dash. I’m thinking it can be a blend door but also some other parts in the AC system. Then after riding around for 10 minutes my AC starts to blow warm then it’ll get cold for a second then immediately back to warm. I have a megacab and the back AC vents blow the hardest. I did the AC test gauge you can buy at an auto parts store and checked my refrigerant it’s good. I’m just lost

[@flopster843]

First thing I would check is the evaporator. Pull out the blower (3 screws) and stick your phone into the box and take a picture. A dirty evaporator can cause a loss of flow. Second would be to watch the drivers while you change modes to see if they are moving properly. You can just barely see them behind the dash from the floor area. They should move the door the full travel. If they do not move enough or keep moving then something is broke inside. The AC temp could be a few different things. 1st, the system could be slightly over or under charged. A proper charge is achieved by completely evacuating the system and doing a full recharge by weight. You cannot accurately charge a 134a system by pressure and those little can gauges are pretty much worthless. There could also be a lack of airflow across the condenser up front. Test this by placing large fan in front of the condenser to see if it makes the system start working. If neither of these help, you'll need to do some more troubleshooting using a good set of gauges and data logging the system. It could be a compressor issue or maybe a clogged orifice tube. Hopefully this at least gives you a place to start.

[@matthewbayles2116]

Thanks man this helps a lot!

[@michaelpalmer2201]

Do you know if a 06 1500 is the same process

[@flopster843]

Yes it will. Everything is the same.

[@michaelpalmer2201]

Thanks

[@jdoconnor8883]

How much does a job like this cost(including new blend doors)?

[@flopster843]

Usually around $1000 depending on the shop.

[@jdoconnor8883]

@@flopster843 Thank you!

[@amandadavis9726]

Looks like I’m next in line😅.

[@Dieselpwr]

It’s a bear but wasn’t too horrible

[@84bdrussell]

3 nuts