I have heard quite a bit about this Blend Door, and after ruining my last
Grand Voyager chasing a non-existant water pump problem, I'll ask first.

The lever/cable is bound up and will only move 1/2 from Hot towards the
Cold position. So, I figure the good old Blend door is jammed. Now I have
heard a lot of lore about the door, but the main qusetion I have is:

WHERE THE HELL IS IT, AND HOW THE HELL CAN I GET TO IT?!?!?!

There. No I'll sit back and wait for the answers to pour in!

Any answers appreciated, of course!

On Wed, 18 Nov 2009 14:45:56 -0500, Hachiroku ãƒ�ãƒ�ãƒ*ク wrote:

Hmmmm...no answers pouring in!

I got the console off, and lubed the cable, and found a TSB describing
how to 'fix' the problem, but I can't get a grasp on where to punch the
hole.

ANYONE have an idea? Other than "Visit your local Dodge Dealer", of
course!

Hachiroku ãƒ�ãƒ�ãƒ*ク wrote:
things stopping short of removing the dashboard, knowing that I will
never put it back right. Finally I took a ride to nearest Dodge dealer.
I do not remember exact number (around $500+,later) the gate was working
again.
Mine (94)had the blend door under the heater and air cond. coil (dealer
told me that they are stacked one on top of the other and the door is at
the very bottom).
In order to remove a piece of plastic (pieces of the passenger side
dashboard vent), heating and air cond coil had to be drained and removed.
Mechanics have a few shortcuts. I do not have a clue, all what they told
me was true and done or not.Maybe they did maybe they did not.

Being in your shoes, I would try to remove the dashboard and you might
see the cable or the blend door.

On Thu, 26 Nov 2009 05:20:59 -0800, Yazoo wrote:


WOW!!!!!!!

It took me a bit of looking (like, THREE DAYS!) but I fanally found a
diagram to go along with the TSB explaining the Blend Door kludge (calling
it a 'repair' is a misnomer...)

You have to remove the center section of the dash where the radio, heater
controls, storage bin, etc are located. Then remove the lower part of the
heat duct 'extension'. At first it looked like you had to unsnap it, and
it is NOT easy to unsnap! THEN I noticed the screws. Remove three screws
and then the ductwork comes off. Then you see what looks like a nipple
coming down from the box. There are two of them, a small one you just
pulled the screw out of to drop the duct, and a larger one. it is the
larger one you drill a hole into and lubricate.

Of course, my blend door was still moveable by the cable, it was just not
moving very freely or very far. If the door is stuck then I can see why
you would have to go all through that, but luckily mine was just binding
and the lubrication seems to have done the trick.

Hachiroku ???? wrote:
FWIW, from my earlier post in my own thread. Obviously, this won't fix a truely
binding door.

Following the procedure here:
http://www.justanswer.com/questions/1l4bf-hi-1994-dodge-caravan-3-slight

It took a #2 philips screwdriver and about 5 minutes to re-adjust the blend door
movement.