NHTSA Complaint #10427507 — 2004 DODGE RAM 1500

THE FRONT WINDSHIELD DEFROSTER WAS NOT BLOWING STRONG ENOUGH TO DEMIST THE WINDSHIELD. I TRIED THE HVAC KNOB ON OTHER SETTINGS, AND THE AIR FLOW WAS VERY WEAK ON ALL THE SETTINGS. UPON REMOVAL OF THE BLOWER MOTOR FROM THE AIR BOX, I DISCOVERED THAT THE RE-CIRCULATION DOOR HAD DROPPED DOWN AND WAS BLOCKING THE AIR FLOW TO THE BLOWER MOTOR. I WAS ABLE TO REMOVE THE RE-CIRCULATION DOOR FROM THE AIR BOX, AND UPON INSPECTION DISCOVERED IT HAD BROKEN AT THE CONNECTION POINT TO THE RE-CIRCULATION ACTUATOR. THE PIECE THAT HAD BROKEN AWAY FROM THE DOOR WAS STILL UP INSIDE THE AIR BOX. HAD THIS PIECE OF PLASTIC FALLEN INTO THE BLOWER MOTOR, IT MAY HAVE DAMAGED THE FAN OR CAUSED AN INJURY. THE HVAC FUNCTIONS WORK FULL STRENGTH NOW, BUT THERE IS NO WAY TO BLOCK THE OUTSIDE AIR FROM COMING INSIDE ON VERY HOT DAYS OR WHEN IT IS SMOKY OR THERE IS AN ODOR OUTSIDE. SOME PEOPLE MAY NOT BE MECHANICALLY ABLE TO FIX THIS PROBLEM ON THEIR OWN, AND I'VE READ THAT THE REPAIR BY THE DEALERSHIP IS EXPENSIVE. SOME PEOPLE HAVE HAD THE DOOR BREAK MULTIPLE TIMES. CHRYSLER CORPORATION SHOULD RECALL THESE VEHICLES AND INSTALL A BETTER DESIGNED AND STRONGER RE-CIRCULATION DOOR. *TR