GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Door Replacement

Removal Procedure
  1. Remove the floor air outlet. Refer to Floor Air Outlet Replacement .
  2. Roll back the instrument panel. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
  3. Remove the clips holding the air distribution case to the heater case.
  4. Remove the clips holding the case halves together.

    5. Object Number: 669159 Size: MH
  5. Separate the air distribution case (16) from heater case (8).
  6. Remove the top half of the air distribution case from the vehicle.
  7. Place the top of the case onto the bench.
  8. Remove the defrost door from the module case.
  9. Disconnect the electrical connector from the mode actuator.

    10. Object Number: 258020 Size: SH
  10. Remove the screws from the mode actuator.
  11. Remove the mode actuator link from the control lever.
  12. Remove the mode actuator from the module.
  13. Remove the defrost door from the module case.

Installation Procedure

    Object Number: 258020 Size: SH
  1. Install the mode actuator to the module.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the screws to the mode actuator.

    3. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  3. Install the mode actuator to the control lever.
  4. Connect the electrical connector to the mode actuator.
  5. Install the defrost door to the module case.

    6. Object Number: 669159 Size: MH
  6. Install the top half of the air distribution case into the vehicle.
  7. Align the air distribution case (16) to the heater case (8).
  8. Install the case clips.
  9. Install the clips holding the air distribution case to the heater case.
  10. Roll the instrument panel forward. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
  11. Install the floor air outlet. Refer to Floor Air Outlet Replacement .