Question about 2004 Chrysler Pacifica

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I have a small plastic part which has broken off

The actuator for the air plenum baffles has broken and I've been told I need a complete air plenum at $2600.00. It seems a little steep, is there any solution.

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I would try plastic weld or jb weld for plastic

Posted on May 08, 2010

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Vents won't blow hot or cold air. Comes from defrost and feet when you put fan on.

It's the vent actuator, it moves the baffle that changes the direction of the air flow.
Here is a video of a broken vacuum hose that creates the same problem.

It could also be a failed actuator.

Sep 19, 2016 | 1997 GMC Safari

2 Answers

2006 nissan quest sl ac blows cold on pass side but not on driver side

I would replace the cabin filter. If it is clogged could be causing faults with the door blend actuator.

Jul 14, 2016 | Nissan Cars & Trucks

1 Answer

Getting diagnostic error code 1004 on 2007 chrysler 300

P1004 is for the performance of the intake plenum's short runner valve actuator. This is an electrical actuator on the intake that opens and closes a valve in the plenum under certain driving conditions to provide better performance. There was a service bulletin for this code and is the first thing that needs to be done. Your dealer may have already done this, or is in the process of completing it with the repair you were quoted. The TSB involves reprogramming the software in the powertrain control module and then checking to see if the short runner valve actuator works correctly. After the software is updated then the actuator is commanded to sweep using the scan tool. If it doesn't sweep correctly then the actuator is removed and the valve is moved by hand. If any binding in the valve is felt then the intake plenum has to be replaced. If no binding is felt and the wiring to the actuator is intact, then the actuator will need to be replaced. It sounds from your description that this is what the dealer is doing. I would say that the software has been updated and they found that the short runner valve was binding, and the plenum needs to be replaced. It wouldn't cost $2,000 though. The plenum itself runs $449 and the labor to replace it shouldn't exceed two hours.

Feb 17, 2011 | 2007 Chrysler 300 AWD Sedan

1 Answer

My heat won;t blow hot air just cold.........what's the problem

The blend door actuator is probably stuck or the gear in the actuator could be stripped. If it is just stuck it can be reached by removing the passenger side air bag assembly and the the adjacent dash support brace. Using a small bent hook on the end of a coathanger pull carefully on the blend door lever until it moves toward you.

If that does not solve the problem you will need to replace the actuator which will require total removal of the dash to gain access to the top of the plenum.

Jan 20, 2011 | 1991 Lincoln Town Car

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Do i have to remove complete dash to replace a heater core in 1992 grand marquis.

Section 12-03: Air Conditioning System 1992 Town Car/Crown Victoria/Grand Marquis Workshop Manual REMOVAL AND INSTALLATION Plenum Removal
  1. Disconnect battery ground cable.
  1. Disconnect the heater hoses from the heater core tubes. Plug the ends of the heater hoses to prevent coolant loss.
  1. Plug heater core tubes securely to prevent coolant leakage from heater core during plenum removal.
  1. Remove three nuts located below the windshield wiper motor retaining the LH end of the plenum to the dash panel (Fig. 15).

FIG. 15 Plenum and Air Inlet Duct Removal


  1. Remove one nut retaining the upper LH corner of the evaporator case to the dash panel.
  1. Remove LH and RH lower instrument panel insulators.
  1. Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment.
  1. Remove all instrument panel retaining screws and pull the instrument panel back as far as possible without disconnecting any wire harnesses.
  1. Loosen the RH door sill plate and remove the RH side cowl trim panel.
  1. On manual systems, disengage the temperature control cable housing from the bracket on top of the plenum. Disconnect the cable from the temperature blend door crank arm. On ATC systems, remove cross body brace and disconnect wiring harness from temperature blend door actuator and disconnect the ATC sensor tube from the evaporator case connector.
  1. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
  1. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
  1. Remove two hush panels.
  1. Remove one plastic push fastener retaining the floor air distribution duct to the LH end of the plenum. Remove LH screw and loosen RH screw on the rear face of the plenum (Fig. 14), and remove the floor air distribution duct.
  1. Remove two nuts from the two studs along the lower flange of the plenum.
  1. Carefully move plenum rearward to allow heater core tubes and the stud at the top of the plenum to clear holes in the dash panel. Remove plenum from vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull lower edge of instrument panel rearward as necessary while rolling the plenum from behind the instrument panel.
  1. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
  1. Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.
  1. Install three nuts on the studs along the lower flange and one on the upper flange of the plenum (Fig. 15).
  1. Install three nuts below the windshield wiper motor to attach the LH end of the plenum to the dash panel.
  1. Install one nut to retain the upper LH corner of the evaporator case to the dash panel.
  1. Position floor air distribution duct on plenum. Install two screws and plastic push fastener.
  1. If removed, position panel door vacuum motor to the mounting bracket. Install two retaining screws.
  1. Connect the white vacuum hose to the outside-recirculating door vacuum motor.
  1. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install floor duct.
  1. Connect the ATC sensor tube to the evaporator case connector on ATC equipped vehicles.
  1. Install the cross body brace and connect wiring harness to the blend door actuator on ATC equipped vehicles.
  1. Connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable as outlined under Adjustments.
  1. Install the bolt to attach the lower RH end of the instrument panel to the side cowl.
  1. Install the RH side cowl trim panel and tighten the RH door sill plate retaining screws.
  1. Install glove compartment door and check arms.
  1. Connect vacuum supply hose to vacuum supply.
  1. Install RH and LH lower instrument panel insulators.
  1. Install two hush panels.
  1. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
  1. Fill the cooling system with coolant to replace coolant lost during removal of the plenum.
  1. Connect the battery ground cable. Check the system for proper operation.

Dec 17, 2010 | 1992 Mercury Grand Marquis

1 Answer

How do I fix a broken ac damper in my 2003 Grand Marquis? For a few days, there would be intermittent clicking behind the dash, related to the car vacuum levels. Now the heater is stuck on, though all...

there should be some plastic covers under the dash (kick pannels) , you will need to remove... Most of the air plenum is located on the passanger side.. so start under the glove box and remove those pieces of plastic first.
When the cover panels are off... opperat the climate controls and listen and look where the noise is comming from... With any luck... you will hear a vacuum hiss and find it is just a cracked vacuum line you need to replace.

Sep 28, 2010 | 2003 Mercury Grand Marquis

2 Answers

Ac does not blow thru dash vents very hard just a little bit of cold air can be felt 05 1500 dodge truck

Dodges have issues with the plenum door actuators. You can read online for more information. Sounds like your plenum door either stopped where it was or went to a default ( closed) position. The plenum door mixes the air and moves to allow the desired temp air to pass thru it.
I think you can see the tip of the actuator shaft sticking down vertically from the bottom of the plenum box, just to the right of the transmission hump, where the passengers left toes would be. Most likely you will have to remove the complete plenum for repair. ( pain in the a**). Good luck.

Sep 08, 2010 | 2005 Dodge Ram 1500

2 Answers

Hot air comes out the passenger side when air condirioning is on.

The control module or actuator is most likely the cause. You can manually set it for cold air until winter. Actuator is under the dash right by the blower.

Aug 20, 2009 | 2004 Chevrolet Silverado

1 Answer

When I turn on the rear heater or air conditioner, I believe it is the actuator makes a clicking sound. I can see the clicking sound is the plastic sprocket skipping.

Easy,your rear blend door actuator is bad. buy one and install it! no problem. it's right on rear plenum,just pull trim off and panel out and sneak it in there.

Jul 18, 2009 | 2004 Ford Expedition

1 Answer


this is correct, there could be two possibilities, one is the blend door actuator which is mounted on the heater plenum and second is the actual blend door could be broken or binding, to check the actuator you need to remove the radio and if you look down at the heater plenum you will see (normally white) electric actuator. remove the actuator by removine the 3 8mm bolts, once it is out plug it back in and check the operation by changing the temperature from hot to cold, if it does move than the problem is in the plenum and will require replacement

Oct 04, 2008 | 1999 Ford Windstar

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