Replace the mode door actuator in the HVAC system to restore proper airflow direction control between defrost, vent, and floor positions.

Warnings

Tools required

Parts

• Mode door actuator × 1 — Mopar 68231264AA or equivalent
• Dashboard trim clips (assorted) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition to OFF position and remove key
3. Disconnect negative battery cable and wait minimum 2 minutes
4. Set HVAC controls to OFF position
5. Allow engine to cool completely if recently operated
6. Prepare workspace with good lighting and organize tools

Procedure

1. 1

   Remove lower dash panel
   Locate the lower dash panel on the driver's side below the steering column. Remove the two T20 Torx screws securing the lower panel. Gently pull the panel away from the dash, releasing the retaining clips. Disconnect any electrical connectors for lights or switches if equipped. Set panel aside in a safe location.
2. 2

   Remove knee bolster
   Remove the knee bolster panel located above the lower dash panel. Remove four T20 Torx screws along the top edge. Carefully pull the bolster forward to release the clips along the bottom edge. Disconnect the hood release cable by sliding the cable end off the lever, then rotating the cable housing to release from the bracket. Set bolster aside.
3. 3

   Access HVAC plenum area
   Looking up into the dash area where the knee bolster was removed, locate the HVAC plenum housing on the driver's side. Use a work light to identify the mode door actuator, which is typically mounted on the driver's side of the plenum with a gray or black plastic housing and a connecting arm to the mode door linkage.
4. 4

   Disconnect actuator electrical connector
   Locate the electrical connector on the mode door actuator. Press the release tab on the connector while pulling it straight away from the actuator. If access is difficult, use needle nose pliers to gently squeeze the release tab. Ensure the connector is completely disconnected and position it out of the way.
5. 5

   Document actuator position
   Before removing the actuator, note the position of the actuator arm and its connection to the mode door linkage. Take a photo with your phone for reference. Observe how the actuator shaft engages with the door linkage to ensure correct reassembly orientation.
6. 6

   Remove actuator mounting screws
   Remove the three screws securing the mode door actuator to the HVAC plenum housing. These are typically Phillips head screws. Support the actuator with one hand while removing the final screw to prevent it from falling. Due to limited access, a short screwdriver or stubby ratchet may be required.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
7. 7

   Disconnect actuator from linkage
   Carefully rotate the actuator to disengage the actuator shaft from the mode door linkage. The shaft typically has a D-shaped or keyed connection. You may need to gently pry or wiggle the actuator while pulling it away from the housing. Be careful not to damage the linkage arm or door mechanism.
8. 8

   Remove old actuator
   Once disconnected from the linkage, carefully maneuver the old actuator out through the dash opening. Navigate around any wiring harnesses or other components. Inspect the linkage connection point for any damage or wear. Clean any dust or debris from the mounting area on the plenum housing.
9. 9

   Prepare new actuator
   Remove the new mode door actuator from packaging. Verify it matches the old actuator in shape, mounting holes, and electrical connector type. Manually rotate the actuator shaft to verify smooth operation. Position the actuator shaft in approximately the same orientation as noted in the photos before beginning installation.
10. 10

    Install new actuator
    Carefully maneuver the new actuator into position through the dash opening. Align the actuator shaft with the mode door linkage, ensuring the D-shaped or keyed connection properly engages. You may need to rotate the door linkage slightly to align. Push the actuator into position against the plenum housing, verifying the mounting holes align.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
11. 11

    Secure actuator mounting screws
    Install the three mounting screws through the actuator into the plenum housing. Start all three screws by hand to ensure proper thread engagement and alignment. Tighten screws in a cross pattern to 15.0 Nm (11.0 lb-ft) using a torque wrench. Verify the actuator is seated flush against the housing and the linkage connection remains properly engaged.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
12. 12

    Reconnect electrical connector
    Reconnect the electrical connector to the new actuator. Push firmly until you hear or feel a positive click indicating the lock tab has engaged. Gently tug on the connector to verify it is securely attached.
13. 13

    Test actuator operation
    Reconnect the negative battery cable. Turn the ignition to the ON position without starting the engine. Set the HVAC controls to AUTO and cycle through all mode positions: panel, bi-level, floor, and defrost. Listen for the actuator motor operating smoothly without binding or unusual noise. Verify each mode change is accompanied by actuator movement.
14. 14

    Reinstall knee bolster
    Reconnect the hood release cable by rotating the cable housing into the bracket and snapping the cable end onto the lever. Position the knee bolster into place and press firmly to engage the lower clips. Install the four T20 Torx screws along the top edge and tighten securely by hand.
15. 15

    Reinstall lower dash panel
    Reconnect any electrical connectors for switches or lights if equipped. Position the lower dash panel and press firmly to engage the retaining clips. Install the two T20 Torx screws and tighten securely. Verify the panel is seated flush with no gaps.

Reassembly

1. Ensure all trim panels are properly seated and clips fully engaged
2. Verify no tools or parts were left in the dash area
3. Confirm all electrical connectors are secured with audible clicks
4. Double-check that hood release cable operates properly

Verification

• Start engine and set HVAC to AUTO mode with fan on medium speed
• Cycle through all mode positions (panel, bi-level, floor, defrost) and verify airflow changes direction correctly at each setting
• Check that airflow comes from correct vents for each mode selection
• Listen for smooth, quiet actuator operation with no grinding or clicking noises
• Verify no air leaks from behind the dash when HVAC fan is operating
• Test in both manual and automatic climate control modes if equipped
• Confirm no warning lights or HVAC error messages on instrument cluster

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