Novak Conversions Jeep Wrangler TJ radiator

03 Wrangler HVAC blend door

johndl58

Member
Original poster
Joined
May 18, 2025
Messages
42
Location
New York
I did a bunch of searching and everything focuses on the actuator motor. My actuator motor is working and the blend door is working correctly. In my research I've found that the foam on the door breaks down and that it can be fixed by cutting a hole to access the door. I can't seem to find anything that shows the exact spot to cut the air box for access. Has anyone done this before? 2003 wrangler.
 
Heater Treater replaces the blend door by cutting a hole in the HVAC box. It's not the method I would use. I would prefer to remove the dash and HVAC box. What type of symptoms are you experiencing?

Yeah I saw the heater treated video but it's not that clear as to where to cut. This Jeep is a beater and I'm definitely not taking the dash apart. It's the usual warm air blowing out of face vents but not on any other settings. Vents work properly as per their respective settings, actuator works properly, and both heater hoses to core are hot.
 
Novak Conversions Jeep Wrangler TJ radiator