1999 Plymouth Grand Voyager or Dodge Caravan Replace Blend Servo Actuator

This is the procedure to remove and replace the AC blend door Actuator/Servo for the blend door which mixes hot and cold air. It is located on the left(driver side) of the AC unit under the dash near the brake and accelerator pedals. Remove seat and plastics first then reach up w 8mm socket to remove cover and actuator. When it fails you will get stuck in one position for temperature.

[@ChrisSmith-we6dx]

...this is the type of non-help infamous on CZcams. attempted this surgery 04-20-24 on my 1999 Voyager. After removing multiple obstacles and spending over 2hrs on back and sideways inside vehicle, there was NO way to access the topmost or #3 screw holding actuator in place from Under or Frontwards or from left or right. Only possible way, down thru the top of dash - requiring disassembly of dash to include instrument cluster. This Video - the new part NOT installed. Key Words, without video "After You Get it Out" and at the End? "Good Luck". This Project would require at least two days for the Home Fix-it Person. a One Minute 36 second Vid for a 5-6 hour job?

[@bowhitegardener3121]

That's the only way to do the job, on your back and twisted around. it helps a little if you take out the driver's seat. Even then, if the ac controller does not actuate it you have to leave it off and clip it into place manually to the position you want.

[@ChrisSmith-we6dx]

@@bowhitegardener3121 I had to disassemble the entire dash. The dashpad (top) removal enabled me to get to the topmost of the three 10mm screws holding the actuator - not possible from underneath. Three hours of disassembly. Having removed and installed the replacement part, a Dorman 60-4010, I then discovered the plug-in port is a mirror opposite to the plug: IT DID NOT FIT. Options were to order another/return defective - but: every option SAME. So, grind down plug to fit? no room unless remove then re-attach. Decided to find CLOSED position (to STOP heat blast) and re-install old part which no longer rotated (stuck) and left plug detached. Result: No options for feet/dash/defrost etc but NO HEAT BLAST. Fan works, defrost only, A/c still 'out' but have been sidetracked with other priorities so have not attempted to re-charge A/c (was at 25psi). Blend control functional at dash. May get Lucky but this Job a NIGHTMARE. "Good Luck". I removed both front seats and entire interior as am 6'3 and 225+, 60+ years old. Only did not have to remove speedometer, in retrospect. Took it out cuz wanted MAX access possible.