Alright... There is good news, bad news, and pictures too.

The good news is RocketQjQ is right. You can remove the blender door motor without removing the dash. Although I have some scars from getting my big hands up into there...

The bad news... no local auto parts stores sell an actual replacement part for the Automatic climate control, only the manualcontrol. That explains why the part I found was sooo cheap ($38 bucks for Dorman 604-100 that DOES NOT Fit). The local dealer wants $220+tax. I laughed in hisear and hung-up. So far the best I've found is online through ebay (approx $85 for brand new part, shipped).

Speaking of the part... According to what I can find, the original part# 16163982 has been replaced by 89018365(seems to be a universal GM part for many makes and models).

Like most folks, my blender motor would work fine if I could just get the main gear replaced or fixed. It has a single crack that allows the shaft to slip (not turn) when the gear turns.

Hope the pictures work... Here goes!

The original part out of the vehicle.
[IMG]local://upfiles/3215/58B9ECD9DC1142BBA60E03B283774558.jpg[/IMG]

Notice the fine crack in the largest gear, just past 6 o'clock.
[IMG]local://upfiles/3215/61A979E2E68549B3B26F834327B29C65.jpg[/IMG]

 

I believe I have to do this same project...Just how tedious is it? any special tools required? And I have absolutely no idea where the thing is....I have the computer climate control with the electric actuator also. How can I be sure this is the problem?

 

According to my manual that is the electric temperature actuator. Sorry, I've been looking at the wrong actutors for you.

On the installation procedure it says to (1) ensure that the actuator is seated on the locating tab.
(2) install the retaining screws
(3) connect the electrical connector
(4) Turn the ignition switch to the off position
(5) Remove the RDO BATT fuse for 10 seconds
(6) Reinstall the RDO BATT fuse
(7) Turn the ign switch to the ON position
(8) Ensure the actuator cycles through the hot and cold range

 

GMPartsDirect.com shows $115 for the RPO C68 auto climate control temp actuator #89018365 (AC Delco #1572971). That is the correct, updated part number for this actuator. And yes, this part gets used on a LOT of other vehicles.

But then again, this topic really was only dealing with manuals... Lets keep things straight here.

 

Sorry for taking us so far off-topic. I was just so excited, I couldn't control my typing