I'm trying to remove the blend door actuator so I can continue trouble shooting. Problem is, there's a floor duct in the way. I've removed the two bolts holding it, but I cannot get it out. How do I remove this thing without cutting the carpet and floor duct?

Also, before I get any further into this project I want to throw out the symptoms this has to make sure it's actually the blend door.

Here's what it does. A/C works great. Heat works not so great and only on the two lowest fan settings. When the fan is turned on high, it blows cold air.
Blend door motor turns in response to the rheostat. No plastic shavings were found on top of the actuator when I pulled it down. Is there anything else that could cause the heat to not work well?

 

Yes, a blocked or restricted heater core.

 

To alloro's point, the heater core valve is either vacuum or manually controlled.
If vacuum controlled, maybe a leak? Not very likely but still a possibility.

 

Does the heat work at all, front-back-defrost? Does it overheat? Our 99 has been doing this for a year, replaced the heater core 2x, checked the blend door, then found out the problem. Cracked Head Gasket. Good luck, that thing is NOT fun to tear apart and put back together.

 

I HAVE HEAT AGAIN!!!!!! I replaced the thermostat, blend door, heater core and the actuator. The blend door was fine, no cracks present so I'm thinking heater core or actuator (though the actuator turned fine, maybe weak?) I still need to assemble the trim and I have a pretty bad coolant leak at the thermostat housing, so I'll need to take that apart again. I replaced the O-ring, so not sure what the problem is there.

I'm really glad to have it working again. Whoever the engineer was that designed this and the floor vent leading to the rear can go to H*LL!!!!! What a p.o.s. design.

 

No valve to the heater core. The heater core is "on" all the time. The blend door blocks the hot side when calling for A/C and blocks the cold air side when calling for heat and swings back and forth to "blend" the two to get the desired temp.

 

I'm glad you said it. I got it wrong one time and judging from everyone's reaction you'd think I just smack the Pope upside the head.

 

I don't like saying it, (cause I'll get smacked ), but sometimes I just gotta speak up or else pretty soon many will start repeating there's a valve in the 2000 Expy heater core.

 

Anyone have input for me. I have heat in the front. Air conditioning doesn't really get cold in front. The rear gets air conditioning gets really cold but I don't get heat in the rear. I hear a popping in the rear blend door. Can this rear blend door cause the issue with the front getting cold?

 

The front and rear are separate issues although both sound like blend door issues. For the front the hinges for the blend door tend to break. For the rear, that clicking is a stripped gear in the blend door motor/driver. There are many topics in the forum related to both of these issues.

 

Sounds like either the blend door motor or door itself is going bad. The door may not be opening/closing all of the way for you to get a/c. Mine had done that on occasion before I replaced it.