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The Third of Three Finally Failed ...

7.9K views 19 replies 11 participants last post by  Impala Mark  
#1 ·
It's common knowledge that 8th Gen Impalas with split left/right HVAC controls are cursed with three identical plastic HVAC actuators manufactured with weak plastic gears, and that all three will fail sooner or later. (The 4th actuator - the Mode actuator - is a completely different design that has never given most of us any grief.)

Well, my third of these three identical actuators finally failed yesterday, and I replaced it this morning. Thankfully, this one, the Passenger-Side Blend Door actuator) was FAR easier to access and swap than the first two (the Driver-Side Blend Door actuator and the Recirculation Door actuator) had been.

Surprise, surprise! This actuator exhibited the same exact failure mode as the previous ones. Two adjacent teeth sheared off the intermediate gear inside the housing, resulting in the thing producing a loud clacking noise as it attempted to reposition past the missing teeth.
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I replaced the failed actuator with one I had rebuilt using an intermediate gear made from much stronger material, just as I had done with the the last failed actuator. Then, I rebuilt this failed unit and put it on the shelf. In the photo above, you can see the two broken teeth next to the failed gear. If you decide to go the rebuild route, instead of continually replacing failed actuators, be sure to fish the broken teeth out of the housing before installing the new gear and closing the thing up again. Leaving the teeth inside there will cause a premature failure if one of them gets caught between two gears.

I used to buy my actuator rebuild kits, which consist of only this gear and a small tube of synthetic grease, directly from the website of the individual who makes them at blenddoor.com. But I've discovered that he now lists them on Amazon, so I buy them from there to get the Amazon points. They're the same $12.99 price either way.

I'm in no way associated with this product other than as a user, but I do recommend it as a less expensive and hopefully much longer lasting solution to the broken actuator problems in these cars.

Cheers!
 
#5 ·
I agree that the passenger side blend actuator is by far the easiest of the three. You don't even need to remove the glove box. Just pull down on the back of the box when opening it to release the two tabs at the top back, and allow it to swing all the way down toward the floor. After you do that, the blend actuator on the passenger side is readily accessible.

IMO, it's almost a toss-up between the other two as to which is the bigger PITA (both are hell and replacing either will result in multiple abrasions and lacerations). But I think I prefer replacing the recirc actuator way over by the right A-pillar than the left side blend actuator, because I'm small and have small hands.
 
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#6 ·
Durn little people. LOL :p If your hands are small enough I can see how the recirc would be easier.

I have big hands so the LH side blend actuator was easier. I've done both and they both had me speaking furrin language. :devilish:
 
#9 ·
Hmm. I wonder if those actuators use the same gear train. The actuators in my 2001 Mustang are different and use a 3-wire connection, but I've never looked inside one. Those are 20 years old and still working fine.

In any event, so far, so good on the gears from BlendDoor.com, but they haven't been in service long enough to comment on longevity.
 
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#4 ·
The passenger side mode and blend actuators are fairly easy to access through the empty glovebox hole. Just pull the glovebox out and put it in the back seat to do these.
The Driver side is not awful but you have to take the knee panel off the bottom of the dash.
Recirc is a colossal PITA. If you don't need recirc just set the door and unplug the drive motor.
 
#2 ·
I am so glad I have so far been able to get by with the reset/fuse trick and just dealing with the occasional hvac weirdness. Tried once to replace an actuator and ended up giving up as my 6 foot 4 inch self is very tough to cram under the passenger dash. With my car being 5 years old now, I expect my luck with the actuators to run out any day now though.
 
#10 ·
I wish I had known earlier about the rebuild. I’ve replaced the passenger side twice, the driver side once and the mode actuator once. My car is a 2012 with 156,000 mi so I guess that isn’t too bad. I think I’ll order the rebuild kit ahead of the next failure. They’re all a PITA in my opinion.
 
#17 ·
If the cabin filter in your Impala is the same as mine, the GM replacement is a paper-only filter. As such, it's not really designed to scrub odors, just particulates. However, there are other brands available that incorporate activated charcoal and/or baking soda layers, which will help in minimizing odors. You might try one of those.
 
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#12 ·
I had to replace the recirc actuator on the 2011 Impala I used to have. The driver side one was going out when the car got hit and totaled by a drunk driver and thus was spared the pain of trying to replace that one. Replacement actuators were pretty cheap on eBay. I think I paid like $8 or $10 for one with free shipping.
 
#15 ·
I bought the AC Delco actuators from RockAuto for my 2011 LT. I haven't had any issues with them and I installed them a couple of years ago. I keep hearing people have issues even after replacing the actuators but I've been finding out that they buy the cheap aftermarket actuators that are around $10 which don't last.