2008 Cobalt: Heater Blend Door Show CF Beginner Thread Starter
Join Date: Jan 2013 Posts: 2 Likes: 0 Received 0 Likes on 0 Posts Thought I had a bad servo to the door that mixes temp. Turns out the servo is good. The shaft that the servo rotates is broken off! Looks like it has been "repaired" in the past as there is glue residue on the broken remnants and there are pieces of the shaft missing. Dealer estimate to repair is $900 but would likely be a couple hundred more as "They wouldn't look forward to performing this repair". Any thoughts or experience with this issue? The purchase of this Cobalt has been a mistake from day one. CF Monarch
Join Date: Apr 2012 Location: Miami, FL. Posts: 5,316 They probably have to remove the dash to do it properly. If this is not a daily driver, then you can do it yourself. Take your time and do it as time permits. CF Beginner Thread Starter
Join Date: Jan 2013 Posts: 2 Likes: 0 Received 0 Likes on 0 Posts No way was I going to pay the local dealer $1200 to replace a $16 blend door. I looked through my junk and found a brass bushing I'd machined for another project and it happened to be the correct i.d. to fit the door shaft. I epoxied the shaft back together using the bushing as a coupling. I also had to trim the white blending cam for the upper servo to clear the bushing. Not very much, just a little on the bench grinder. I'd post pictures but I cannot seem to upload them. It was a major pain to do this as I was on my head fitting it all together. However, it works and it cost about ten bucks.
CF Beginner
Join Date: Feb 2014 Posts: 2 Likes: 0 Received 0 Likes on 0 Posts I fixed mine using a piece of 1/2" copper pipe from Lowe's ($6) to make a sleeve for it. I had to buy a 2 foot piece because I could not find a smaller piece. You have to be sure to buy the actual pipe, not one of the couplings because the inside diameter is larger on couplings. I took the end of the plastic shaft that was broken off with me to make sure it fit. I then just purchased some epoxy (also at Lowe's in the paint/caulk section). The key is to make sure that you line up the piece that broke off with the other side of the shaft, it was easy for me because it was not a clean break, it was more of a diagonal break making it clear how it was supposed to line up. The reason alignment matters between the broken pieces is because it can impact how the servo and blend door align. The servo position is set by the temperature dial and the blend door needs to correspond to the dial setting (hot position vs cold position and everything in between), improper alignment could also cause it to break again since there are mechanical limits on blend door movement. If you are not to tell how it goes back together, you can manually flip the door to either "full hot" or "full cold", then set the temperature dial to match and make sure the end of the shaft will fit into the servo opening (it is keyed). I hope this helps. I worked out great for me and only took about 10 minutes. CF Beginner
Join Date: Oct 2015 Posts: 3 Likes: 0 Received 0 Likes on 0 Posts Quote: Originally Posted by oldchevy They probably have to remove the dash to do it properly. If this is not a daily driver, then you can do it yourself. Take your time and do it as time permits. The blend door is under the dash and you can see the box where the blend door and actuator are located, between the driver and passenger foot wells. I removed the blend door actuator to find that the post on the blend door is totally sheared off. There is not even anything that I could even try and hook into. As such, it appears that I will have to get in there and totally replace the blend door. First issue is, I cannot find a blend door at local parts places, so I may have to go to a dealer to get it. Second, I have been unable to find anything that explains how to replace that type of blend door. I can find the one that is behind the glove box, but not the one that is down between the driver and passenger foot wells, at the very bottom of the dash. If anyone knows of a source of information on how to do this, I would greatly appreciate it. CF Beginner
Join Date: Feb 2016 Posts: 1 Likes: 0 Received 0 Likes on 0 Posts You wrote that the repair took 10 minutes. Did this include taking the dashboard out? I can't see anyway to fix it unless I remove the dashboard. Please let me know. CF Beginner
Join Date: Feb 2014 Posts: 2 Likes: 0 Received 0 Likes on 0 Posts Quote: Originally Posted by iggy13 You wrote that the repair took 10 minutes. Did this include taking the dashboard out? I can't see anyway to fix it unless I remove the dashboard. Please let me know. I did not have to take out the dash. The actuator is accessible from the driver side floorboard. You have to get your head down near the pedals then look towards the passenger side and you should see the actuator. I no longer have this car so I can't take any pictures, but remember that it was easy to locate and remove. The actuator should be good, it is the blend door shaft, which the actuator rotates, that is likely broken. Take the broken piece with you to fit test with the pipe you will buy to sleeve it. If it turns out the blend door shaft is completely sheared off, then this "easy" repair will not work for you and the dash will have to come out to replace the blend door. You will know for sure once you remove the actuator. Good luck!! Super Moderator
Join Date: Mar 2011 Posts: 8,757 very clever repair. gm engineering has done a similar type of repair on the 2006 equinox. if may work on the cobalt. they sell a sleeve that is made to slide over the broken blend door and fit into the actuator splines. the sleeve is around $10 and installation requires making a cut in the hvac box with a hole saw tool. the sleeve works better than a new door as it stops the over cinching of the door which breaks the shaft. repair time is 1 hour if the door has not fallen into the hvac box. 3hrs if its fallen into the box. other repair methods such as blend door replacement is probably a 6-8 hour job Last edited by tech2; February 14th, 2016 at 11:24 AM. CF Beginner
Join Date: Apr 2020 Posts: 1 Likes: 0 Received 0 Likes on 0 Posts
Quote: Originally Posted by dougtex28 I fixed mine using a piece of 1/2" copper pipe from Lowe's ($6) to make a sleeve for it. I had to buy a 2 foot piece because I could not find a smaller piece. You have to be sure to buy the actual pipe, not one of the couplings because the inside diameter is larger on couplings. I took the end of the plastic shaft that was broken off with me to make sure it fit. I then just purchased some epoxy (also at Lowe's in the paint/caulk section). The key is to make sure that you line up the piece that broke off with the other side of the shaft, it was easy for me because it was not a clean break, it was more of a diagonal break making it clear how it was supposed to line up. The reason alignment matters between the broken pieces is because it can impact how the servo and blend door align. The servo position is set by the temperature dial and the blend door needs to correspond to the dial setting (hot position vs cold position and everything in between), improper alignment could also cause it to break again since there are mechanical limits on blend door movement. If you are not to tell how it goes back together, you can manually flip the door to either "full hot" or "full cold", then set the temperature dial to match and make sure the end of the shaft will fit into the servo opening (it is keyed). I hope this helps. I worked out great for me and only took about 10 minutes. Hey I was wondering how do I change it from full hot to full cold on my 2008 Chevy Cobalt LT manually. Thank you Thread Thread Starter Forum Last Post Tristan Equinox 6 August 5th, 2021 8:08 PM foxnettles Impala 3 October 1st, 2011 2:05 PM wally3b4 Venture 0 February 25th, 2011 5:55 PM los7883 Tahoe & Suburban 0 April 12th, 2010 10:36 AM scesfiremedic OLD - Private 'Wanted' Classifieds 0 February 13th, 2009 6:20 PM 2008, blend, blender, chevrolet, chevy, cobalt, defaust, door, heat, heater, kit, located, repair, replacement, temperature, working Where is the blend door actuator located?The blend door actuator(s) are typically located on the climate control case behind the dashboard.
What is the difference between blend door and blend door actuator?The blend door can open and close at various positions to block or allow air passing through the heater core in order to achieve the desired temperature inside of the vehicle. The blend door actuator is typically located closer to the heater core and evaporator than the mode door.
Are there two blend door actuators?There can also be two blend door actuators in your car if you have a newer model. If your backseat has controls to the temperature and airflow intensity, then your car will have two blend door actuators.
How do I know if I need a new blend door actuator?A faint clicking or droning sound underneath the dash is usually a blend door actuator noise. This noise may be obvious when you switch on your vehicle AC system or turn on the climate control dial. Most times, switching the climate control dial can temporarily stop the noise.
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2008 Chevy Cobalt blend door actuator location
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