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.
Sparky:
I changed the driver side actuator and went through the manual calibration and the air would only come through the defroster. Do I have another acuator issue?
GM states to disconnect the battery. I would recommend waiting ten minutes after the battery is disconnected before working with the airbag components.
Great Post. I have a 2004 Z66 Avalanche that needs the passengeer side actuator replaced. Although it looks involved the pictures and instructions seem very complete and make it look not that complicated. EXCEPT for one question. What are the “Manufacturers Directions” for disabling the SRS and removing the Air Bag? Or where can I get them?
You will need to get prepared for when the actuator will swing to the full cold position. Remove the dash face trim panel. remove the driver’s right vent assembly. Remove the radio. Make sure you have the theftlock code before disconnecting the radio wires. Using a couple of long screwdrivers or whatever else will work for you reach under the duct and disconnect the harness from the actuator while it is in the full cold position. Try to do it quickly and cleanly as it is almost impossible to reconnect the harness to try again. If needed do a recalibration procedure and/or disconnect the wiring (repeat several times) at the passenger end of the dash under the end cap.
Sparky,
Is there a wire harness connection that leads to the passenger actuator that is accessible without removing the dash? It seems both my actuators have failed and I need to take a road trip. I disconnected the drivers actuator as it was blowing cold air, and would like to do the same until i get money and time to replace them.
It was all working fine today until I took it to the dealer to find out if they could reprogram the HVAC controller. They reported that both units needed to be replaced but I never had an issue with the passenger just the drivers side. My hope was for them to reprogram the control unit because I found a service bulletin 06-01-38-003 about the hvac issues and it described my issues exactly. Sadly $100 later that only seems to have made it worse. I dont’ have the $1400 they want to replace them both so I will have to save to attempt to repair myself.
Your blog is amazing, thank you so much for sharing your experience and if you are ever in Virginia I’ll buy you a beer or few.
David