Recirculation Door Actuator

Remove and replace the HVAC recirculation door actuator, which controls fresh air versus recirculated cabin air mode in the climate control system.

Warnings

Tools required

Parts

• HVAC recirculation door actuator × 1 — Mopar 68028736AA or equivalent

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition off and remove key
3. Disconnect negative battery terminal and wait 2 minutes
4. Allow HVAC system to cool completely if recently operated

Procedure

1. 1

   Remove passenger lower dash trim panel
   Locate the passenger side lower dash trim panel (knee bolster). Remove the trim panel fasteners using a 7mm socket. The panel is typically secured with 3-4 fasteners along the upper edge. Once fasteners are removed, carefully pull the panel away from the dash to release any remaining retaining clips. Disconnect any electrical connectors for the passenger airbag indicator light if equipped, then remove the panel from the vehicle.
2. 2

   Access HVAC housing area
   With the lower trim removed, locate the HVAC housing behind the passenger side of the dash. The recirculation door actuator is mounted on the HVAC case; verify the exact location on the 2008 Viper HVAC housing (commonly near the blower/inlet area) using service documentation before proceeding. Use a flashlight to identify the actuator, which is a small electric motor with a plastic gear arm and an electrical connector. You may need to reach up and behind the dash structure to access it.
3. 3

   Disconnect actuator electrical connector
   Locate the electrical connector on the recirculation door actuator. Press the locking tab on the connector and pull it straight away from the actuator. If access is limited, use needle-nose pliers to depress the tab while pulling the connector. Ensure the connector is fully disconnected and positioned away from the work area.
4. 4

   Remove actuator mounting fasteners
   The recirculation door actuator is secured to the HVAC housing with 2 screws. Using a 7mm socket and ratchet, remove both mounting screws. Work carefully in the confined space, maintaining pressure on the socket to avoid dropping fasteners into the dash cavity. Set the screws aside in a secure location.
5. 5

   Remove actuator from HVAC housing
   Once the mounting screws are removed, carefully rotate and pull the actuator away from the HVAC housing. The actuator drive arm engages with the recirculation door linkage, so you may need to rotate the actuator slightly to disengage the connection. Gently work the actuator free without forcing it. If resistance is felt, verify the drive arm alignment and adjust as needed. Remove the actuator from the vehicle.
6. 6

   Inspect door linkage and housing
   With the actuator removed, inspect the recirculation door linkage mechanism inside the HVAC housing. Verify the door moves freely by hand and is not binding or broken. Check the mounting surface on the HVAC housing for cracks or damage. Ensure no debris has fallen into the housing opening during removal.
7. 7

   Install new actuator
   Position the new recirculation door actuator to align with the door linkage. The actuator drive arm must engage properly with the linkage connection point. Rotate the actuator as needed to mesh the drive arm with the door mechanism. Once aligned, press the actuator gently against the HVAC housing mounting surface, ensuring it seats fully.
8. 8

   Install actuator mounting fasteners
   Install the 2 mounting screws through the actuator and into the HVAC housing. Start both screws by hand to ensure proper thread engagement. Using a 7mm socket and ratchet, tighten the screws evenly in an alternating pattern until snug. Do not overtighten, as the plastic housing can strip.
9. 9

   Reconnect electrical connector
   Reconnect the electrical connector to the recirculation door actuator. Push the connector firmly onto the actuator terminals until the locking tab clicks into place. Gently tug on the connector to verify it is securely latched.
10. 10

    Reinstall passenger lower dash trim panel
    Reconnect any electrical connectors for the passenger airbag indicator light if previously disconnected. Position the passenger lower dash trim panel against the dash structure, engaging any retaining clips. Install the trim panel fasteners and tighten with a 7mm socket until snug. Verify the panel is flush and secure.
11. 11

    Reconnect battery and initialize system
    Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine. Cycle the HVAC recirculation control through all positions (fresh air and recirculate) several times and verify the door moves fully in each position. Note that this manual HVAC system does not perform an automatic self-calibration routine. Listen for smooth operation without clicking or binding noises.

Reassembly

1. Reassembly is covered in the procedure steps above
2. Ensure all electrical connectors are fully seated and latched
3. Verify trim panels are secure and aligned properly before testing system

Verification

• Start the engine and turn on the HVAC system
• Press the recirculation button and verify the indicator light changes state
• Listen for the actuator operating smoothly without excessive noise or clicking
• Test both fresh air and recirculation modes to confirm proper door movement
• Check for proper airflow changes between modes (recirculation mode should feel slightly different)
• Verify no dashboard rattles or loose trim panels after reassembly

Related trouble codes on this vehicle

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