I have a / ticking / bubbling / burbling sound coming from behind the dash and decided to replace the four HVAC blend door actuators per tech bulletin JTB00066. I have replaced all of them except for the Recirculation (Cold Air Bypass) actuator and still have the noise. I was hoping not to have to replace this one as it appears it will be tough to get to. The factory service manual just says remove the screws and replace. Not quite. If I lay on my back, I can stick my hand way up into the dash and touch the connector and one of the screws and feel the actuator running continuously.

Has anyone ever replaced this actuator and do you have any tips, or do I just need a short stubby 8mm wrench and lots of patience and hope that, if I can get the old one out, I'll be able to get the new one in?

Send a PM to our tech: Brutal.

Bgsgross, thanks for the idea. I have sent Brutal a PM.

Er... in general there's a tech / site plea NOT to do that. The techs get too many but also when they post they add to what others can learn / find using Search whereas a PM does not.

I gave up on replacing them. Way too tough. I have the air flow fixed on the front vents only.
Even that was a PITA.

Yes, they are a pain, but three of them weren't that bad. The service manual could be a little more detailed on some the steps, especially the one behind the instrument panel. I found I also had to remove the plastic duct behind the panel, and to remove the duct, I had to remove the side window defrost vent on top of the dash in order to get to a screw. Once that was out, it was a breeze.