Jeep Wrangler TJ blender broke again; fix it so the A/C blows cold in my face

[@CarbonsDIYGarage]

Check out the video description for extra info, parts, tools, torques, and any updates.

[@jimhaller6386]

Where did you order the Lever Part? Working on a 2004 Jeep Wrangler X and having problems locating the right part?

[@CarbonsDIYGarage]

@@jimhaller6386 Parts info and Amazon link is in the video description. Thanks for watching!

[@jimhaller6386]

I checked out the part and on our 2004 Jeep Wangler X it looks like a different set up.

[@CarbonsDIYGarage]

@@jimhaller6386 Ah, yeah. Quite possible. I know the parts list works for ‘97-‘99. I’m not much help for the years after that. Maybe you can find one for the ‘04 out there. I did find a link to one for the ‘02: www.scribd.com/document/52091475/Jeep-wrangler-2002-Parts-List

[@andrewmcfarland57]

Took my new (to me) TJ out the the OHV and bounced it around a bunch, and it came home with a broken blend door. Thanks for making this not turn into a nightmare repair. Perfect video.

[@CarbonsDIYGarage]

Sounds like a great trip! These blend doors seem to be so touchy! I'm glad the video is helpful. Thanks for watching, Andrew.

[@leosky38912]

Thank you for this video. The vent lever broke on me twice. It was really helpful to have this video... especially when i noticed I had the actuators backwards BEFORE I tested it!!!

[@CarbonsDIYGarage]

Glad it helped! Thanks for watching, Leo.

[@ForceBuilt]

Great camera angles. I imagine that wasn't easy to film. Great job Ed!

[@CarbonsDIYGarage]

Thanks, Steve! Definitely need to be a contortionist to work in some of these areas. I actually used the camera (through the gap under the steering wheel) as a way to see what I was doing (and create footage for folks) instead of cramming my head down by the pedals.

[@dannyfinn556]

Thank you for taking time to make and post this video!!!

[@CarbonsDIYGarage]

Thanks for watching, Danny.

[@Chilling-b9z]

Thank you for posting this. I have the same problem; air don't come out the front. I wouldn't have a clue what to do.

[@CarbonsDIYGarage]

Glad the video was helpful. Thanks for watching and good luck with the fix.

[@benl6777]

Thanks. Gonna try this tomorrow on my 05 TJ

[@CarbonsDIYGarage]

Good luck with it. Thanks for watching.

[@gerryward7654]

Great camera work.

[@CarbonsDIYGarage]

Thanks for watching!

[@jlathem56]

Thanks for sharing your knowledge! Very helpful.

[@CarbonsDIYGarage]

Thanks for watching. I’m glad it’s helpful.

[@TurkeySandwichJr]

Hey thanks for this. Mine was actually broken off right at the keyed square part of the arm. I was able to thread a wood screw in a couple turns and pull it out with pliers. Glad it already had a hole in the center, dunno how I'd have pulled it out otherwise!

[@CarbonsDIYGarage]

Glad you were able to get it out and thanks for the tip for others. Thanks, too, for watching.

[@onemeangreen]

Broke my arms again. Going to try drilling tapping and a screw in my new ones.

[@CarbonsDIYGarage]

Oof! I wish these things didn't break so easily! I wonder what causes it - the actuators just pulling/pushing too hard/too far? Good luck with the fix.

[@DanH616]

Thanks again for these! Just did defroster top one, and front vents have about 1/3 air flow, and nothing out of the floor. I am hoping to find the same one here broken as in video, but everything is in place and moving. very frustrating

[@CarbonsDIYGarage]

Oh that’s super frustrating! It sounds like you already checked that the doors move full travel when you change the selector setting. If they didn’t, the vacuum actuator might be the culprit or a vacuum leak. But if they’re all fully traveling… could it be the fan? Sorry, I’m out of ideas on this one.

[@DanH616]

@@CarbonsDIYGarage thx for the support! I am going to verify the lever is actually moving the doors next. Video I took shows smooth operation after replacing Defrost one, but doesnt confirm the others are seated and moving the door. That HAS to be it.

[@RodManson-gi6jl]

Hi there , how did you get the broken half out of that lever hole ? its stuck on mine and i dont want to break somthing .thanks for your nice instruction !

[@CarbonsDIYGarage]

I was fortunate (?) in that the broken end was nowhere to be found. Either it pushed through into the a/c box at some point, or it came out at some point before I bought the Jeep. In other videos, I’ve seen people take a screw, screw it into the remnants of the plastic arm stuck in the a/c box, and use that to pull it out. I don’t have experience with that personally, though. Sorry. Thanks for watching and good luck!

[@RodManson-gi6jl]

yep thanks for advice ,already drilled the screw but its stuck as stone ,maybe i try to drop it in to the hole as yours was already done. much appreciation✌

[@dougphillips8389]

Great video, what is the part number for the floor door actuator (highlighted in GREEN)?

[@CarbonsDIYGarage]

Doug, are you looking for the part number for the actuator itself, or the plastic lever? According to the Parts list for my '97 (which covers '97 - '99), the vacuum actuator is part number 4864995, the same part as the Panel Door actuator. For the Floor Door actuator lever, the best I can tell, from this post (www.jeepforum.com/threads/what-does-this-hvac-vacuum-arm-attach-to.1420604/post-14220732), the lever is the same part number as the lever for the Panel Door actuator. If that's true, you would need the same lever part number as is linked in the description of this video (Omix-Ada 17910.02 HVAC Door Lever (amzn.to/3I3x5o6)) I hope that helps and works for you. Good luck and thanks for watching.

[@dougphillips8389]

@Carbon's DIY Garage yes sir, I was looking for the plastic piece for that actuator that the arm attaches too.. but ithink you answered it in your message back to me..I have a 97 as well and it's a total wreck internally. Previous owner just let everything go to crap. I have already replaced all of the big 3 oil gaskets, oil pump, water pump, water pump housing, thermostat. Now working on the heater core and the bolts are freely turning to the hvac box in the engine bay.. got to figure a way to get that out. During that process I broke heater cable thingy that looks like one of the pieces from your video but it is under the passenger side, heater cable is bent, can't find one anywhere. Oh and the hold down bolt for the distributor I can't get enough leverage to take it out to prime the oil pump. Anyway, sorry to vent but thank very much for your reply and information.

[@CarbonsDIYGarage]

@@dougphillips8389 Oh man! Previous Owner sure did a number on your TJ; sorry to hear it! I haven't had the (dis)pleasure of having to remove the heater core or hvac box (or the entire dash just to get access). For the '97 TJ, the temperature control cable (that goes from the a/c temperature control slider to the plastic actuator lever) is part number 55037398AA. But I think you're looking for the plastic actuator lever. For the '97 TJ, it's part number 4864990. Here's a link to where I think you can buy one, though I've never purchased from this site before (jeeppartsoutlet.com/1997-jeep-wrangler-se-gas_2.5_4-transmission_manual_5-hvac-evaporator_heater_components-lever_4864990-item/). I did find this forum post on it that might help (wranglertjforum.com/threads/please-help-me-find-this-heater-cable-lever-part.29951/post-483261). Good luck with your project(s)! And I catch the venting pun there in your last sentence... 😂

[@joshuajones48]

Thanks for videos. It is really helpful. I have a question. When I took my jeep apart I found that all three of my levers are broken. Do you happen to have the part number for the one closest to the floor?? I am not having any luck finding it. Thanks in advance.

[@CarbonsDIYGarage]

I actually just dug into this question earlier in the week to answer a similar comment/question down below. Here's what I came up with: According to the Parts list for my '97 (which covers '97 - '99), the vacuum actuator is part number 4864995, the same part as the Panel Door actuator. For the Floor Door actuator lever, the best I can tell, from this post (www.jeepforum.com/threads/what-does-this-hvac-vacuum-arm-attach-to.1420604/post-14220732), the lever is the same part number as the lever for the Panel Door actuator. If that's true, you would need the same lever part number as is linked in the description of this video (Omix-Ada 17910.02 HVAC Door Lever (amzn.to/3I3x5o6)) I hope that helps and works for you. Good luck and thanks for watching.

[@joshuajones48]

Thank you

[@jimhaller6386]

Joshua, Did you ever locate the parts you were looking for? I am having troubles tracking down the same part for a 2004 Jeep Wrangler X.

[@GlenHoover-fb7cm]

where did you get this actuator lever? A part number too, please.

[@CarbonsDIYGarage]

Thanks for watching, Glen. Parts info is in the video description. There's also a link to another video I've done on the same topic, which also has additional parts info.

[@rikkir6229]

How do you remove an arm that isn't broken in that spot? Any idea?

[@CarbonsDIYGarage]

I'm pretty sure there's a little lip at the end of the arm that, when the lever is pushed all the way in, will drop down and basically lock the lever in place so it can't easily be removed. I don't see a good/easy way to slip a little screwdriver in there to try to lift that little arm up to 'unlock' it. I think the only option is probably to use a pair of needle nose pliers and pull (hard?) to get it out and hope the little plastic arm doesn't break? Or maybe run a longer wood/drywall screw into the middle (there's a little hole) and then use pliers to pull out on the screw? The screw method would have you pulling from the center so that might work better. If the little lever arm breaks, you can probably push it all the way through/into the a/c box (it might even drop out the floor vent) but then you've also broken that lever and need to buy a new one. Not great answers; might give you ideas, though. Thanks for watching the video; can you thumbs up it if it's earned it? (maybe even subscribe?)

[@johnsimpson4099]

Bro..my 2004 Jeep Wrangler sport 4.0 blows air while on any AC setting at the floor and dash vents..wtf parts do I need to fix it? I have changed the control module, evaporator , compressor, dryer , all o rings and it still blows like 56 degrees at idle. But the vent thing is what drives me nuts..plus it reads 40 degrees on the gauges

[@CarbonsDIYGarage]

Thanks for watching, John. Seems like there are a couple of questions here. I'm not smart/expert on system pressures, oils, etc. so I don't think I can help you with the actual temp of the a/c. Checkout @ForceBuilt. Steve has a few videos on a/c on his TJ that might help you. For getting the air to flow to the face/panel vents, it sounds like it's a problem with the panel/door. It could be the actuator part just like I describe and show in this video. It might be a different part number, though, for that plastic piece because the 1997 - 1999 TJs have a lot of differences from the newer TJs. Sorry; I don't know that info. It could also be the vacuum actuator or the door internal to the a/c box (which would suck the most). If you haven't, get your head under the steering wheel and watch the actuators move when you cycle between defrost, panel/face, and floor. All 3 actuator arms should move in/out varying amounts based on setting. If one doesn't move, that might be what's broken. If all 3 move, then it might be that the plastic actuator lever is broken, just like in this video. If all the motion is good and the lever is securely in place into the a/c box, then it might be the door inside the a/c box itself. I don't believe that's an easily replaceable part (have never looked into it that much). You'd have to pull the a/c box out of the Jeep to get it open, I'm sure. Sorry it's not a magical answer but that's the best I know and what I'd do to try to figure it out. Good luck!

[@victory4real611]

Did you remove your driver seat to do this or can it be done with seat in?

[@CarbonsDIYGarage]

Definitely did it with the seat in. It’s probably easier access/more elbow room if you remove the seat but mine are so rusted in, though, I truly fear the day I ever have to try to remove them. Thanks for watching!

[@Dan-440]

Wow. Great video. I sure don't look forward to squeezing in to that small area, but at least I can get it done now. Thank you.

[@jjballestrini]

Where did you get the leaver arms?

[@CarbonsDIYGarage]

Info and link to the part is in the video description. Be sure you get the correct part number for the specific arm you need to replace. Also check out the first video I did replacing one of the levers: kzbin.info/www/bejne/m6G8pINsnb1lmpY Thanks for watching, Joey, and good luck with yours!

[@Christian_30]

What if it only comes out of the defrost in every position?

[@CarbonsDIYGarage]

I think I would first get underneath the dash (or stick a camera down there) and see if the 3 actuator doors move as you move the slider through the various positions. If they do move, can you also hear the doors moving? If one or more never moves, you might have a bad actuator or a vacuum leak. You can also pretty easily tell by watching them if any of those plastic connector arm is broken like mine was in the video. This is what I’d do on my ‘97 but if you have a newer model year it might be a little different. The service manual also has a diagram of where the doors are located and maybe even troubleshooting (I don’t recall off hand). I hope that helps a little. Good luck. Thanks for watching.

[@Christian_30]

The vacuum line is broken at the T

[@CarbonsDIYGarage]

@@Christian_30 Oof! That'll definitely do it, but finding it is probably the hardest part. Hope you can get it up all patched up easily.

[@Christian_30]

Thank you for your help

[@DBNEBMUSICGROUP]

I have a 1993 jeep xj and it's been very difficult to find these parts. Any suggestions anyone?

[@CarbonsDIYGarage]

Thanks for watching. The part numbers for the actuator levers is in the video description as well as a link to Amazon for one of them (the other part number is also on Amazon). Hope that helps.

[@frangiew9076]

Bi-level vents

[@1964JEDAGI]

My floor actuator doesn't work. The actuator doesn't move in or out. I can move it manually with my hand. I guess I need to test the actuator itself by pulling a vacuum on it first.

[@CarbonsDIYGarage]

Yeah, try swapping the vacuum connections between an actuator that works and the one that doesn’t and then move the blend selector and see if your broken actuator now works. If it works, I’d say your vacuum line to that actuator has an issue. If it still doesn’t work, it must be the actuator. Good luck and thanks for watching.

[@1964JEDAGI]

@@CarbonsDIYGarage yes sir, I thought about that after the fact. Behind the glove box the vacuum lines harness goes in towards the firewall. Do you know where it goes or how to get to it? I could get in the floorboard and see if I can see up behind the the ducts. I'm a big fella and it's kinda tricky getting in that position. LoL I've had some rat activity back in there. I need to see if any of the lines got chewed.

[@CarbonsDIYGarage]

@@1964JEDAGI I know exactly where you’re talking about. Take a look at this video at the 1:22 mark. kzbin.info/www/bejne/b6rWgHaYm86nZpI By my thumb is a small black tube. That’s the vacuum line for the actuator on that side of the vehicle. At least that’s it for my ‘97. You’re absolutely right - getting a hand up in there around the a/c ducting on the inside requires contortion. I hope that helps.

[@1964JEDAGI]

@@CarbonsDIYGarage Yes, once it goes through the firewall it joins with something that turns into the six colored lines. FYI, I'm in north east Texas near Paris. My jeep is a 98 TJ with the 4.0 litre.

[@CarbonsDIYGarage]

@@1964JEDAGI Ah, I gotcha. Sorry, I’ve been lucky to not have had to dig into that harness of colors. That does not sound like a fun chore, sorry to say.