Blend Door, 1992 Caravan

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!
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On Wed, 18 Nov 2009 14:45:56 -0500, Hachiroku ハチロク 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! ;)
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Hachiroku ハチロク wrote:

Good luck. I tried to get access to it for a few days, I removed a few 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.
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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.
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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.
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