The blending door breaks where it is attached to a small motor, This part is too weak which causes the mounting flange to split and the motor turns inside the door flange, this is why others say it no longer works. In my case it split apart allowing a small piece of the coupling into the motor blower causing the fan to vibrate. You can temporarily fix the problem by taking the Door out, (IT's EASY). Remove the three screws holding the fan motor (Under glove Box) Unplug the wire feed power to the motor. Then you can reach up and remove the door. This takes some maneuvering of the door through the hole where the fan is. THE SOLUTION: Purchase the Blending Door $40 at the dealership (They Have them in stock, Their service dept needs them for all the problems they have with the truck). You get the case and door and small motor as a unit. Take the motor off the new part and where your last part broke, Take plastic apoxy from the parts store and beefup the coupling at the point where it splits or breaks on the door. (NOTE: You can also repair the one that broke with the epoxy - your choice - Same work ) INSTALATION: ALSO EASY, Not worth $300- $500 to pay the dealership. First take your clove box door off - this is done by opening it pushing the stops on boths sides of the box and allowing the door to open further and the box comes off. Second take motor fan off, three screws and elec plug. Third you can see on top of the heater/ ac box the small motor on the side of the case ubove the identification sticker. This is the motor that turns the blending door, Take this off (two screws hold it) this is what allows the door to come off once you pull the motor off. Fourth feed the fixed or new reinforced door into the hole where the fan motor was and align it into the hole opposite of the motor side. Then put the motor back in aligning the coupling so it works properly. then replace the motor screws. Test without the fan motor installed to make sure it is all working, if it is, install the fan motor back and put the glove box back. your done. On a scale to 1 - 10 this is a 2 and should take you 1 hour or less, you will take most of your time putting the Blend door back and aligning it, there was a total of 5 screws (Phillips screw driver type) and an elec plug on the fan motor.

Update from Jan 27, 2010: Has the fix worked (YES) -- I have not had another issue since I fixed it. I have some pictures I have attached that might help. follow the instructions in my complaint and go up through the fan hole. this is the blending door. in the pic I show the little elec motor while in the truck looking through glove box opening. the others show how I fixed it. Make sure your pull the little motor and the white plastic coupling out of the box (where the motor is attached). this will help pull the door off in side the box through the fan hole and put the door back in through the fan hole.

Robert

I bought my ram in 2006, in 7/2007 I took it in to have the ac fixed. It was explained to me that the blend door (this is the part that regulates the air that flows into the cab of the truck) was not working correctly and they would repair. In 7/2008 the ac was not working properly again, I took in for evaluation, again it was explained that the blend door was broken. This time they replaced the defective part. Unfortunately I drive a long distance to my job each day (70mi), due to this when the repair was done in 2008 the mileage on my ram was over what is still covered by warranty. The dealership offered me what they called "good will assistance" to assist in covering the cost of repairs. Well here we are in 2009 and AGAIN I am having a problem with the ac. I took my ram to the dealership and they found that the blend door was broken AGAIN!!!!! This time I have 68,000 miles on my ram and no way will it be covered by warranty. I was told the cost would be approx. $500 to repair. I was told to contact Chrysler to see if they would help with the repair. Called Chrysler, after being shuffled around on hold for about 20mins and then being disconnected, just to have to call back and then be put on hold for another 10mins they came to the conclusion that they would not be able to help, because the dealership already assisted me the previous year for the same repair. Needless to say I am very upset because I believe this situation is due to a product defect or mechanical error on the part of the dealership that replaced the broken part. When I pay to have this fixed and then it happens again next year or again in the future, is Chrysler then going to recognize this as the product defect that I complained about? Will I be reimburse? If anyone is having this same issue please post on this web site.