08 Dodge Caravan HVAC blender door actuator gear

thingiverse

This is a common failure for Dodge vehicles that affects numerous models. My vehicle made a clicking noise when switching from hot to cold and got stuck on hot, then continued making this noise for around 10 minutes, sometimes even with the engine turned off and key removed. This incident occurred on the driver's side during a three-hour road trip, which was not enjoyable at all. To fix this issue, grease the gear before reinstalling it, and don't forget to calibrate the actuator when reinstalling or it may strip again. This solution should also work for other models with the same actuator, including Dodge Ram, Avenger, Caravan, Town & Country, etc. Printer Settings: Printer Brand: MakerBot Printer: MakerBot Replicator 2 Rafts: No Supports: No Resolution: 0.2 mm Infill: 95 Notes: This model was printed with two shells using ABS for added durability. Although ReplicatorG detected a hole in the mesh, it printed just fine. Post-Printing: Clean up: After printing, use a drill to clear the center bore with an 11/64" bit size. Use a small triangle file to clean up the teeth lightly if necessary. I only had to run the file through the larger diameter gear teeth very lightly to square them up.