Fixed Driver / Passenger Temperature Difference, '02 T&C

I struggled with Driver's side AC being warm for a few months. Independent mechanic said doors were fine, must take to dealer to diagnose. Dealer said AC compressor needs replaced, $1,000.

I noticed that temperature difference (driver side HOT) was intermittently significant even on VENT setting (no AC) and that I couldn't ever get hot air to passenger side.

So, I got under there (driver side, under dash) and looked at door operation and after replacing blend door actuators (because they did not SEEM to operate smoothly) I finally deduced that there was an EXTRA piece in the actuator gearing.

This piece was on the passenger blend door actuator shaft and was interfering with the driver blend door cam gears. I now think the piece is from a SINGLE ZONE climate control system and some yahoo put it in this DUAL ZONE car at some point. I know there was a yahoo under there before me because the Heater Core cover was cracked from said yahoo not noticing that there were three screws holding it in place, not two.

If you have this problem (temp difference between driver and passenger side) do check that the blend door mechanism doesn't have that extra piece over the passenger door shaft. Slim possibility, but I have seen this issue mentioned here before.

Removing a free piece of plastic is a lot more cost-effective than a $1,000 compressor which wouldn't fix the problem anyway.

Best of luck to all.

Mark

Yahoo? I'd have choicer names. Thanks for passing that along. I'm sure it will save a headache or two. Hope you flip the bird at that dealership as you drive by..and they wonder why dealerships are at the bottom of the barrel with lawyers.