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Air Door Actuators 1 Air Door ActuatorsControls A C Blend Door Control Arms pg 25 54 CV Joint Boots Accessories pg 55 66 Door Lock Actuators pg 67 72 Exhaust Manifold Kits pg 73 134 Clock Springs pg 21 24 Don t Get Left in the Cold Applications begin on page 2 Redesigned housing lasts longer and prevents comebacks Controls the flow and temperature of air into the interior of the vehicle 9 SKUs cover over 25 million Ford GM and Jeep vehicles Activant Path Activant Code DOE Heating System Heater Valves Cores Blowers Common Symptoms of Failed Actuators Heat or air conditioning will only work on one side of vehicle Defrost function may not work at all Air Door Actuators 2 Air Door Actuators Fluid Reservoirs pg 139 142 Four Wheel Drive Components pg 143 148 Fuel Lines pg 149 154 Fan Clutch pg 135 136 Fan Pulley Brackets pg 137 138 Visit us at www DormanProducts com Air Door Actuators 604 001 Jeep Grand Cherokee 2004 99 604 100 GM C K S Series Trucks 2006 93 604 101 GM SUVs and C K Series Trucks 2002 99 604 102 GM SUVs and C K Series Trucks 2002 88 604 103 GM SUVs and C K Series Trucks 2002 91 604 200 Ford E Series Vans Windstar 2004 96 604 201 Ford Explorer Ranger w Automatic A C Control 2003 98 604 202 Ford Explorer Ranger w Manual A C Control 2006 98 604 203 Ford Windstar 2003 99 BUICK SKYLARK 1991 604 100 CADILLAC ESCALADE 2006 03Rear A C Controls Exc EXT Series604 100 2002 00 604 101 CHEVROLET BERETTA 1996 91 604 100 CORSICA 1996 91 604 100 LUMINA APV 1996 93 604 100 CHEVROLET TRUCK ASTRO 2005 96 604 100 AVALANCHE 2002 604 101 CHEVROLET TRUCK continued BLAZER 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 C K SERIES PICKUP 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 1990 88Manual A C Controls 604 102 EXPRESS VAN 2006 03Rear A C Controls 604 100 2002 96 604 100 S10 BLAZER 2005 04Manual A C Controls 604 100 2003 98Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls wo HD Heater 604 104 S10 PICKUP 2004 Manual A C Controls 604 100 2003 98Manual A C Controls w HD Heater 604 100 Air Door Actuator Applications Make Model YearsDescription Dorman Make Model YearsDescription Dorman Air Door Actuators 3 Air Door Actuators Fuel Sending Units pg 155 176 Controls A C Blend Door Fuel Tanks pg 177 228 Harmonic Balancers pg 229 254 Heater Hose Assemblies pg 255 256 Hydraulic Clutch Lines pg 257 260 CHEVROLET TRUCK continued S10 PICKUP continued 1997 95Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls wo HD Heater 604 104 1994 604 100 SILVERADO 2002 99 604 101 SUBURBAN 2006 03Rear A C Controls 604 100 2002 00 604 101 2002 00Rear A C Controls 604 100 1999 98Rear A C Controls 604 100 1999 98RHD 4WD Manual A C Controls 604 104 1997 95Rear A C Controls 604 100 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 1994 92Rear A C Controls 604 100 TAHOE 2006 034 Door Rear A C Controls 604 100 2002 00 604 101 2002 004 Door Rear A C Controls 604 100 1999 984 Door Rear A C Controls 604 100 1999 98RHD 4WD Manual A C Controls 604 104 1997 954 Door Rear A C Controls 604 100 TOPKICK KODIAK 2003 Label No 52479669 604 100 2002 96Air Circulator 604 103 2002 96Mode Valve 604 102 1995 91Dealer Installed Air Conditioning Condenser Air Circulator 604 103 1995 90Exc Dealer Installed Air Conditioning Condenser Mode Valve 604 102 FORD TRUCK E SERIES VAN 2004 To 1 13 04 604 200 2003 97 604 200 E SUPER DUTY 2001 97 604 200 EXPEDITION 2004 02Auxiliary Unit Blend Door 604 202 EXPLORER 2006 03Sport Sport Trac 604 202 2002 Au xiliary Unit Blend Door Exc Sport Sport Trac To 10 29 01 604 202 2002 Sport Sport Trac 604 202 2001 Automatic A C Control 604 201 2001 Manual A C Control Exc Sport Sport Trac604 202 2001 Sport Sport Trac 604 202 2000 98Automatic A C Control 604 201 2000 98Manual A C Control 604 202 RANGER 2006 04 604 202 2003 01Automatic A C Control 604 201 2000 Automatic A C Control 604 201 2000 Manual A C Control To 3 1 00 604 202 1999 98Automatic A C Control 604 201 1999 98Manual A C Control 604 202 WINDSTAR 2003 99Front Air Conditioning Unit 604 203 1998 96 604 200 GMC TRUCK C K SERIES PICKUP 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 1990 88Manual A C Controls 604 102 DENALI 2002 01 604 101 DENALI XL 2002 01 604 101 S15 JIMMY 2001 98Manual A C Controls w HD Heater 604 100 GMC TRUCK continued S15 JIMMY continued 1997 95Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls wo HD Heater 604 104 S15 SONOMA 2004 Manual A C Controls 604 100 2003 98Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls w HD Heater 604 100 1997 95Manual A C Controls wo HD Heater 604 104 1994 604 100 SAFARI 2005 96 604 100 SAVANA VAN 2006 03Rear A C Controls 604 100 2002 96 604 100 SIERRA 2002 99 604 101 SUBURBAN 1999 98Rear A C Controls 604 100 1999 98RHD 4WD Manual A C Controls 604 104 1997 95Rear A C Controls 604 100 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 1994 92Rear A C Controls 604 100 TOPKICK KODIAK 2003 Label No 52479669 604 100 2002 96Air Circulator 604 103 2002 96Mode Valve 604 102 1995 91Dealer Installed Air Conditioning Condenser Air Circulator 604 103 1995 90Exc Dealer Installed Air Conditioning Condenser Mode Valve 604 102 YUKON 2006 034 Door Rear A C Controls 604 100 2002 00 604 101 2002 004 Door Rear A C Controls 604 100 1999 984 Door Rear A C Controls 604 100 1999 98RHD 4WD Manual A C Controls 604 104 1994 924 Door Rear A C Controls 604 100 1994 92Manual A C Controls Air Circulator 604 103 1994 92Manual A C Controls Mode Valve 604 102 YUKON XL 2006 03Rear A C Controls 604 100 2002 01 604 101 2002 01Rear A C Controls 604 100 JEEP GRAND CHEROKEE 2004 99Automatic A C Controls 604 001 LINCOLN NAVIGATOR 2004 02Auxiliary Unit Blend Door 604 202 MERCURY MOUNTAINEER 2002 Auxiliary Unit Blend Door To 10 29 01604 202 2001 98Automatic A C Control 604 201 2001 98 Manual A C Control 604 202 OLDSMOBILE BRAVADA 2001 98Manual A C Controls w HD Heater 604 100 1997 96Manual A C Controls w HD Heater 604 100 1997 96Manual A C Controls wo HD Heater 604 104 SILHOUETTE 1996 93 604 100 PONTIAC BONNEVILLE 1999 96Automatic A C Controls 604 104 TRANS SPORT 1996 93 604 100 Make Model YearsDescription Dorman Make Model YearsDescription Dorman Air Door Actuator Applications Air Door Actuators 4 Air Door Actuators Oil Pans pg 303 316 Visit us at www DormanProducts com Ignition Distributor Assemblies pg 261 272 Intake Manifold Kits pg 273 276 Latches pg 277 280 Oil Cooler Line Assemblies pg 281 302 The Heater Blend Door located in the vehicle s heater case allows airflow tempera tures to be adjusted by varying the position of the blend door The 2004 97 Ford Taurus Explorer Mercury Sable Mercury Mountaineer 2004 00 Lincoln Aviator and Ford Ranger can develop problems with the Blend Door The Blend Door pivot pins located at the top and bottom of the door have a tendency to break causing the door to fall apart hang up and jam Up until now the only repair was to replace the entire heater case assembly The original heater case is glued together and difficult to separate for a repair The Heater Blend Door Repair Kit part number 76807 provides a much more cost efficient way to repair the heater door case assembly This kit has been engineered to replace just the broken door and avoids the costly replacement of the whole heater case assembly The kit includes a template for cutting the case retaining screws for the guide plate 2 replacement doors pick the one that matches the vehicle s defective one and an upper plate with sealing gasket Below is a copy of the instruction sheet that has been developed to aid the service dealer in a trouble free repair Related Sales Heater Blend Door Kit Read and Follow All Instructions Carefully Remove the heater case assembly according to the procedure outlined in the shop manual Locate the guide plate in the package and place on the top of the heater case above the broken blend door HINT All 4 holes on the heater case will line up with the holes in the guide plate Secure the guide plate to the heater case with 4 screws provided Using the plate opening as a guide position the cutting tool vertically against the guide plate outline and begin cutting the case straight down Continue to follow the outline of the guide plate as you are cutting until the section on the heater case is loose Remove the cutaway section from the heater case and discard Remove and discard the broken blend door Be sure to remove all broken parts from the case to prevent the replacement door from binding Select the appropriate matching door and insert into the heater case use only 1 door Remove the protective backing from the new retaining plate Press the retaining plate down firmly making sure the blend door pivot is in place Reinstall the heater case per the procedure outlined in the shop manual 76809 2005 97 Ford E Series Van 2001 97 E Super Duty 76807 2006 96 Ford Taurus Sable 2005 95 Explorer 2006 95 Ranger 2005 03 Aviator 2005 97 Mountaineer
