This 2004 Chevrolet Silverado came in with a faulty passenger side blend door actuator. In the last post I got you to this point. If you have not yet read that post please click here. Now that the dash cover is off and you can see the actuator, but you still cannot get to it. More things need to come apart.
Remove the wiring hold down clips from the metal brackets as shown below.
Remove the 7 mm headed screws from the brackets on the passenger side.
Using a ratchet remove the two 10 mm headed screws from the front edges of the bracket on the passenger side.
Remove the 7mm screw from the driver’s side of the cross over bracket. Remove the bracket.
Now the “U” shaped bracket on the passenger side can be removed.
Remove the 7 mm screws on the driver’s side bracket. I also remove the two 10 mm bolts on the driver’s side bracket to make sure the dash will move around freely.
Disable the air bag or SRS system according to the manufacturers directions. Then remove the two upper 10 mm bolts from the air bag as shown in the next two pictures.
Then remove the two lower air bag screws.
Note that the air bag screws are shorter than the bracket screws. Do Not put the long bolts back in the airbag when reassembling.
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Pull the orange "positive assurance clip" from the yellow connector. Disconnect the connector and remove the airbag. Use the manufacturers recommendations for handling and storing the airbag.
Getting close but more still has to come out. The silver box shown below is the vehicle communication interface module. It may not be present on all vehicles as it is related to the Onstar System.
There are three 10 mm nuts that hold the module to the brackets. They are locking nuts so they have to be wrenched all of the way off.
Remove the two 10 mm nuts at the passenger end of the dash carrier. Do Not mix these nuts up with the ones removed from the VCIM brackets.
Now remove the 7 mm screw from the backside of the right passenger vent.
Remove the 7 mm screw from the position shown below.
Wiggle the corner of the dash out as shown below.
I used a screwdriver handle to keep the duct work lifted.
I also used a pry bar to lift the duct work slightly to give myself more room. The weight of the pry bar is enough to keep the duct work up but you may want someone to hold it for you. If someone hold it for you be sure they do not use the area in the center of the opening for a fulcrum. It will break the mounting panel where the nut is for the phillips headed screw that was removed much earlier.
The VCIM can now be wiggled up and the wires disconnected.
Remove the wiring harness retaining clip from the bracket as shown below.
Remove the wiring harness clip from the cross bar as shown in the two pictures below. Lift the harness slightly to gain more room to work.
Using a short 5.5 mm socket and ratchet, remove the two mounting screws. Disconnect the wiring from the actuator before removing the screws. makes it a little easier.
You will actually need to work through two openings and use both hands to make it easier.
A magnet on a stick works real well fro retrieving dropped screws and sockets.
You can finally remove the actuator from the dash.
Free at last.
The new and old actuators. The numbers match 52402588.
If you need to buy one of these actuators please click here.
If you do not have a Tech 2 or similar scan tool to diagnose these actuators, you can do voltmeter testing at these connectors. That is a whole other post though.
Sweet professional job; but I just stuck my arm up through the glove box hole with a 1/4 ratchet and 5/16 socket after removing the glove box, stuck my other hand through the center heater duct after popping the duct out, took the two 5/16ths sheet metal screws out of the blend door actuator and pulled it out. It took about 25 minutes. I will say however that I am an experienced aircraft mechanic and can work by feel without looking at the item, as you have to do many times when you get your hands on something but cannot look at it at the same time. I can definitely be done without tearing your entire dash apart.
I think you will find the information you need at the following post address. There are some variables on the part number and I would recommend looking at the number on the actuator to match it up.
http://www.sparkys-answers.com/2009/09/2004-chevrolet-tahoe-blows-hot-air.html
I was curious as to how my situation related to this one. I have a 2001 1500 HD LS, with the center console. My AC used to turn on after a short period of time after selected(usually five min, and up to that point would be very hot), and then it would work as it was supposed to. Now however the compressor kicks on, and the air only blows hot, even when I switch the temp selector to cold and I have the recirculating air off. It comes out through all of the vents that are appropriate to the selected mode. I tried your actuator reset method, unfortunately to no avail. Being as my truck is not a typical 1500, where would I find the blend actuator, and does it sound like this is the correct fix? The dealer said it would be upwards of $300 to $400 dollars to fix the problem, which seems rediculous to me. Thank you so much in advance.
Thanks!!!
In 2007 the Tahoe body changed and the procedure is completely different. I have not had to do one of these yet but my understanding is that once the passenger side airbag is removed, it is accessed through that opening. I would recommend using the manufacturer’s procedures for disabling and removing the airbag.