Passenger side blend door actuator replacement: Tahoe, Yukon, Suburban, 1500

Tips on tools and technique for replacing the passenger side blend door actuator on a 2004 Tahoe (or similar). removing the air bag and not damaging the dash or air ducts.
Replacing this part was the fix for my Tahoe blowing only hot air on the passenger side.

[@bobhilker8921]

Just finished this job on my '04 silverado, took about 2.5 hrs. Could not have done it without making a tool like you did. Thank You very much !!!

[@TheModelmaker123]

I watched several other videos before seeing this one. Unfortunately, I stopped watching when you showed the part in and I said to myself nothing new in this video, except that he must have been able to use a pry bar to fit the socket over the screw. Well, I went at it, and there was no prying the vent up enough. I ended up making a tool nearly identical to what you did by accident. I kept grinding away the socket and when it still wouldn't work, I tack welded it to a flat bar. I came back to report this and noticed that later on in the video you reveal the tool. Sorry for not staying the entire time. Anyway if you added a note in you description or show the tool early on it would be great for others. Judging by the number of actuators sold, perhaps we should get a few hundred made for sale.

[@howtragic1976]

This worked took us 45 minutes to remove. 20 minutes to get back in. Thanks for the video

[@robanderson4137]

Just watching this video is daunting...now I have to actually do the work...in 110 heat awesome.

[@abee_ls_g8230]

Right! Lol

[@adamshamsuddin]

Fastest way to get this done without cutting the vent with a saws-all is to go ahead and remove the dash (not that bad a job - lots of videos out there), and then loosen the bolts holding the air vent in place. Take a long pry bar through the air bag hole and use the metal bracket for leverage to lift up the vent and you'll have plenty of clearance to do the work with a normal 1/4" ratchet.

[@darladunn875]

I don't understand why everything in the world was removed from the dash.

[@HeSavesMankind]

Put a socket by itself on the head of the screw. Then take a long handle pair of pliars and unscrew it little by little.

[@StrayEyeStudiosInc]

I did this but with a very thin handled flathead, only way I could have room with my hands.

[@izzymang9015]

Bro I had gotten a 03 Tahoe ac was blowing cold asf but then it just gave out completely no defrost no vent no nothing I opened up the vent to see a zip tie and some kind of gear together missing connectors it's were it goes... the actuator

[@checkc131]

Of course it would be this actuator I need to get to. This looks like a PITA and I have a short temper when it comes to shit like this. Better than paying a mechanic I guess. Thanks for the video.

[@redneckgames]

Almost half way through this job. Following your same tips. I appreciate this video. I have the near screw loose and the back one is half way there. Aggravating job!

[@Valdemar-Perez-III]

Heater cores a bitch too

[@infaroot]

The ancient Chinese secret now use a flat blade screwdriver burn a slot into the plastic at the 5.5mm bolts There's enough meat there if you're able to tighten and loosen the bolts

[@cmongimme]

Great video! Question: did you turn the new parts spindle to match position of old part before installing? And if so, is that done from outside of new unit without causing damage or should unit be opened?? Thanks!

[@erminiauviedo2]

I matched the position when I got the old part out.

[@KeithsTVHD1]

Thanks 4 this video my front passenger vents on my 04 Yukon blow heat sometimes and with the summer coming this is a must do job for me.

[@paulkaufman4901]

Thank You so much for showing this! I really didn't want to remove the dash top because it always causes damage regardless of how carefully the work is done. I also didn't want to saw the duct in 1/2 and then tape it back together. After watching Your video, I have a plan for making this happen without the aforementioned destruction. All I have to do is buy the part and muster up a little patience 😊

[@James-wb2ln]

You pull the dash cober off and unbolt the ducts. Easy easy no need to remove airbag

[@captainobvious2062]

Effin aye right broteen shake. You have no idea of the bullshit I have went through with all the videos trying to figure out my situation .actually uou probably know exactly the aggravation involved. on top of all of that it's fucking nightmare . Riding around in 18° the other night sucked coupled with myself getting hit by a pick-uptruck standing in the door of mine. My door got peeled open,and wont shut all the way. So yeah cold ride,and ready to get this heat fixed. Bacon saved hopefully 🤘

[@williamabate7581]

Did your airbag light come on afterwards from unplugging and plugging it in?

[@tylerwatts1649]

Excellent video and tips--thanks

[@domnickewilkins3700]

Thank you sir for the video! Much appreciated

[@Large_Sarge]

Thank you. Didn't want to cut my duct if I didn't have to. Great video.

[@JOSERODRIGUEZ-rz5bj]

What's the ac Delco part number for this. I have a 2005 Tahoe

[@justinvanburen8259]

Hell, yeah, that’s awesome. Great idea.!!!!

[@craigtheporcupine3449]

went to replace this today, previous owner had already went at the airduct with a sawzall, wouldn't have done that myself but took advantage of the situation.

[@KeithsTVHD1]

Did you have to take the airbag fuse out?

[@joshs1525]

Knowing my luck the damn airbag would blow in my face 🤣

[@tsdorsey]

Thank you. Was not willing to cut up the vent.

[@ernestofundora8437]

Thanks

[@nicholaskruegel8313]

Is it a 4 or 5 terminal?

[@ShasnGillespie]

How many blend door our door

[@Steven_Will]

4

[@gregoryduvall4758]

I just changed mine. All I had to do was remove three bolts from the Shroud under the glove box.... then undo the three bolts from the actuator I did not have to take apart all the stuff that you did..

[@gregoryduvall4758]

I stand corrected this is a different actuator

[@Ipponduro]

@@gregoryduvall4758 It sounds like you changed the drivers side actuator which is ironically located near the passenger floor board. I changed mine out several months before the passenger side actuator also failed.

[@T_B_C_L]

Do you know the part number for the actuator

[@Ipponduro]

This one is a Dorman 604-112, it is the same part# for both passenger and driver side.

[@erminiauviedo2]

@@Ipponduro After going to the GM parts dealership, they told me I need AC Delco Part 8901-8365, which is about $250. AutoZone matched the part to 604-106. Hope this helps

[@yamaharxz7]

@@erminiauviedo2 i change mine 2 years ago with an AC DELCO it was not cheap .and now is blowing hot air on the passenger side again, I will go with a Dorman part this time. but I took my whole dash apart last time. but this time I will try it the way this video.

[@ordulf7193]

rockauto.com has multiple economy options

[@morpheus8164]

Erminia Uviedo 7

[@MrJacobCastro]

Take the dash off

[@brianlee677]

I'm doing this on an 04 escalade but I already have the top dash out but still can't get to it might have to try your method.

[@dragomistu]

Is that the driver side blend door actuator? Thanks for the tip, great video!

[@shmeltex]

The actuator in the video is for the passenger side. Driver side actuation is on the bottom of the console on the passenger side and much easier to get to.

[@Ipponduro]

This video is for the passenger side actuator. I have previously changed the drivers side actuator on my Tahoe, and found it's difficulty level not worthy of a KZbin video.

[@danielbeaty]

Any ideas for those of us who don't have access to welding equipment? Anyone feel like selling me one or letting me borrow one?

[@shmeltex]

@Daniel Beaty, I used Gearwrench Pass Thru ratchet www.amazon.com/GearWrench-891400-Ratchet-Locking-Flex-Head/dp/B000TDAIW8/ and socket www.amazon.com/gp/product/B000HBAIUY. It is not as low profile as a self-made tool is shown in the video but gets pretty close, plus it is a ratchet. I changed actuator in under an hour and a half without pulling airbag out.

[@checkc131]

@@shmeltex how did you do it without pulling the airbag? I am about to attempt this and the less work I have to do the better.

[@shmeltex]

@@checkc131 It possible to get to all screws through the vent opening. Video helps to figure out where they are. Use low profile ratchet as I mentioned above and patience. Before you begin try to recalibrate AC and see if actuator actually broken or it just not calibrated properly.

[@o06908]

@@shmeltex Not on a 2003 Tahoe