Blend Door Actuator Gear 2006-2013 Chevy Impala

thingiverse

The actuator units in 2006-2013 Impalas have a tendency to strip the teeth off the central idler gear. I personally replaced one faulty actuator for $25, but it stripped out again within a year. Recently, two out of three actuators failed simultaneously, prompting me to consider replacement alternatives. Instead of purchasing new units, I decided to print the gears to replace them, finding it worthwhile despite the tricky access. A failing actuator causes an intermittent clicking sound that persists for several minutes when starting the car or adjusting the air temperature or source. This part specifically addresses the central idler gear, as it was the component that failed in both of my faulty actuators.