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Typically to repair a broken blend door in the Chevy Tahoe, the dash must be disassembled and the plenum box extracted from the vehicle. It is a very labor intensive process, expensive, and replaces the OEM blend door with the same plastic door that is likely to break again in the future. There are other options available online. One such kit is the HeaterTreater. These guys developed sound instructions combined with sturdy steel hardware to fix the broken blend door without dashboard removal, and at a much cheaper cost. It is also worth checking the actuator motor, as those fail often.

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Where is the Tahoe blend door actuator?

The blend door actuator on the late model Chevy Tahoe is located behind the dash in the glove box area. Broken blend doors and broken blend door actuators are a very common problem among Chevy Tahoe, Suburban, and Silverado models. Typically, to repair a broken blend door, a mechanic will disassemble the dash and replace the plenum box. It is an expensive and labor intensive repair. There are also some DIY solutions such as the heatertreater that provide hardware and instructions for performing the repair by removing the glove box rather than the entire dash. It is worth looking into if you think you have a broken blend door.


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It sounds like the problem is a broken blend door. Before replacing the thermostat or any other component of the Windstar's HVAC system, be sure to check your blend door for functionality FIRST. The most common issue with heat or A/C in the late model Ford windstar is a broken blend door. A broken blend door actuator is almost as common as a broken blend door itself. Typically, the fix requires disassembling the entire dash and replacing the whole plenum box, which can be a costly repair.


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2000 ford explorer heater fan motor makes a noise like a leaf is in it?

This is a symptom of a broken blend door. Typically, to fix a broken blend door, a mechanic will disassemble the dash and replace the entire plenum box. It is very labor and parts intensive. There is a DIY solution called heatertreater, which provides instructions on how to replace the blend door, accessing the plenum box by removing the glove box rather than the entire dash. It is a much better method to repair a broken blend door than removing the entire dash and replacing the broken door with another dysfunctional plenum assembly that will break again over time. That is why Aluminum blend doors, recirculation doors and modes doors would be preferred over the plastic OEM blend doors.


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