After asking a few questions to mechanics, parts counter people, friends, etc., I found some so-called fixes on the internet. One was a DIY'er that had the recirculation door broke off and was blocking the air flow significantly into the cab. He dropped the blower motor, let it rest on the floorboard, stuck his hand up in the cavity and was able to pull the broken door out. He has no recirculation mode, but at least, like mine, he now has full air flow into the cab.

The problem is...I have other problems beside this. I have an actuator or DC servo motor bad, and another blend door is broke. Luckily the motor that went bad is not the one behind the metal structure, but was easier to get to. I replaced the motor with the recirculation door motor since I would not need it anymore. Let's be very clear here though. Replacing the motors is one thing and can be done with the right tools, time, money, and perseverance, but it really makes me mad when I am seeing the same problems from 1999 to 2010, and I'm sure this is not a complete list! Chrysler refuses to fix this problem that they know about. I am not about to take time to get my VIN number for this complaint because they know all about it. Chrysler is laughing all the way to the bank! They know the cheap plastic they use (good plastic with high tech resins and or fiberglass would last a lifetime) will last through the warranty period.

Replacing these doors is a major job. I would much rather replace a head gasket than replace these doors! When I have finally had enough ( when other doors break) I will get a vehicle that doesn't have this history.

1. You'll need a good camera to take pictures before you start and during disassembly 2. If you don't have a garage, roll your toolbox out to your truck, you'll need everything in there, plus more. 3. I hope you have a dremel tool to saw the plastic, sharp chisel to break the spot welds, drill driver to remove the many, many screws, 4. You'll need to buy freon and refrigerant oil so you can recharge the system. 5. Did I mention lots of money for parts, tools, supplies, etc.? 6. I hope you don't have to drive your vehicle because it may be down a bit! 6. Be sure your pickup bed is empty because you'll need the space for all the parts of your vehicle you'll need to store in there.

The truth of this whole dismal decision of the Chrysler corporation to know about this and to keep making their vehicles like this is criminal! My 1947 Pontiac had a better heat and air distribution system than my Dodge has! Like most cars of that day, everything was made to last a lifetime. It had metal vent doors and a steel cable attached to a lever on the dash. This next part is very high tech so please read carefully...the fresh was achieved by a special door in back of the hood that opened via a lever under the dash! Wow, what an innovation!

I just bought my 2004 dodge ram 1500 5.7L used with 105,000M and noticed the air flow was weak coming out of the vents. Even though I heard the fan running strong. i knew something wasn't right. After researching online i found a common problem is the recirculating door breaks and would fall on top of the blower fan restricting air flow. I went under the glovebox and removed the blower motor reached up and of course the door was lying right there over the opening. I took a pair of Dykes and cut the center of the door and then broke it in half and pulled it out. Now the air flow strong A/C and Heat work great. Only down side is I'm pulling air from inside and out. Instead of either or. Easy fix took 10 minutes.