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Blend Door Repair (Heater Box Aluminum)

[Saab 95]

On 95 model cars an issue exist which causes the blend door for the air mixture to fail causing you to not be able to adjust the inside temperature. Error code B2295-B2495 is the failure code for Tech2 (the Saab scan tool). What causes the problem is that the Blend door shaft gets broken which causes the blend door not to move correctly. The repair of this problem through Saab would require the entire disassembly of the dash and replacement of the heater box (usually cost around 2500.00). This fix requires minor disassembly and should not take more than a couple of hours to complete. You can actually make your own out of pvc pipe but we have seen some issues with the reliablility of this repair. Below is a several pictures of the plastic make your own version but we HIGHLY recommend buying our Aluminum version so you can this job as a permanent fix. We want to show you both options and let you make your mind up for yourself.

The blend door kit shown below are made in-house and have proven to be an excellent permanent solution. Use our blend door instead of the white pictured version. You simply slide our Blend door over the broken yellow piece. We have also discovered that the aluminum versions of the Blend door seem to come apart over time that is why we now make an unbreakable two piece unit.

The finished job here will shown our blend door instead of the white piece. Our blend door kit simply slides over the yellow broken piece.

A repair part and process, manufactured from aluminum as shown attached to the servo above, has been developed. Without the new process 10 to 15 hours of labor is required to remove and replace the heater box.

The new process can be completed in the vehicle in less than 2 hours (not sure what a dealer would charge though). First one must gain access to the servomotor by removing the lower dash cover on the affected side. The process shown is for the left side. Remove the servomotor and vent elbow. Next remove the stop lever. by pressing down slightly on the lock tab and pulling it straight off. If the stop lever is missing don't worry about it, as it is integral to the New repair part.

To facilitate reassembly, it is a good idea to index the stepper motor. We suggest you use the repair piece as a tool to rotate the stepper motor shaft. Refer to the picture above. You will want to position the stop arm over the screw that is shown just to the left of the stop arm in the picture. Be aware that it takes quite a bit of torque to get the stepper motor to start turning, but once it starts to move, it goes easier.

Reach inside the case, removing the broken shaft from within.

Insert the new repair piece in the same manner as shown below supporting the bell crank area of the blend door shaft with your left hand.

While supporting the other part of the broken shaft from within the case, press our blend door kit into the housing.
Reinstall elbow, and stepper motor. Replace any covers removed.

NOTE: Be aware that the green bushing in the picture at the top of the page also fails. It is part number 4869244. The replacement is white. SEE Service Bulletin 854-2461 for details.

Clear the codes in the ACC system using the Tech 2 tool and recalibrate the system. If you do not have a Tech 2 just recalibrate by pressing auto and off simultaneously. Make sure the recirculation door operates correctly and that the system is full of refrigerant, because your customer has no idea how many different ways the air conditioner can fail. The link arm for the recirculation door breaks on occasion. Its part number is 4869426. No TECH 2? On calibration the left side of the display will indicate the number of faults, 0-23 and the right side will provide a fault code. 6, 7, and 8 are associated with the left blend door. 6 is an open or short in the stepper motor, 7 is a jammed blend door or motor, and 8 means the shaft is broken. This is the code you will usually see when you need this kit. The right side codes are 9, 10, and 11 respectively. You may or may not get a code 21 associated with the recirculation door link arm.

Pricing for VENTILATION BLEND DOOR REPAIR KIT (cabin fan & related)
Pricing for VENTILATION BLEND DOOR REPAIR KIT (heating & cooling system)

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