Re: Air Recirculation system broken actuator parts
Since I wrote this, the belcrank on mine broke. Dodge, MB or Valeo (that's who makes the air distribution system) do not offer the small bits and piece parts. By happenstance, I found a company that 3D printed a replacement belcrank for me. It's a perfect fit and has been installed for several months without any problems.
Working on it isn't hard, but it is time consuming because you are mostly working by feel due to the location of the parts.
The actuator is held in by two screws, a vacuum line and an electrical connector. Remove the fasteners first, then you will have better access to the actuator to remove the connector and vacuum line.
The belcrank is notched on the actuator end at a location that keeps it from becoming disengaged.
Here is how I installed replacement belcrank and actuator:
The actuator has to be fully retracted during installation to give you the necessary room. I used safety wire to keep it fully retracted until it is fully installed and the flapper arm is installed onto the belcrank pin. The full retract position is also the recirculation position - flapper door closed.
Install the belcrank onto the actuator end. Carefully install the belcrank/actuator assembly onto the belcrank shaft. Do not try to fit the pin into the flapper lever - it gets installed as the last step.
After the belcrank is in place on the shaft, install the actuator fasteners, connector and vacuum lines.
Using a long screwdriver, long thin yard stick - push/deflect/slightly bend the flapper lever enough to fit over the pin on the belcrank. I would recommend applying heat from a hair dryer to make it more pliable.
If I could have easily removed the flapper lever, I would have. I believe it is held into the flapper door by lock tabs, but I didn't want to risk any damage.
Remove the safety wire from the actuator and test operation.
Hope this helps.
Bruce