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Old 02-07-2011, 10:17 AM
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Join Date: Nov 2009
Location: Johnson City, TN
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Vehicle: 2004 Dakota Club Cab 4X4
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Engine: 2002-2008 226ci (3.7L) Magnum/PowerTech V6 215hp 235lb/ft
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It could be a problem with the actuator itself. Check this out:

A/C HEATER CONTROLS
  1. Connect the test set vacuum probe to the HVAC vacuum supply (black) tube in the engine compartment. Position the test set gauge so that it can be viewed from the passenger compartment.
  2. Place the a/c heater mode control switch knob to each mode position, one position at a time, and pause after each selection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each selection is made. If not OK, a component or vacuum line in the vacuum circuit of the selected mode has a leak. See Locating Vacuum Leaks below. CAUTION: Do not use lubricant on the switch ports or in the holes in the plug, as lubricant will ruin the vacuum valve in the switch. A drop of clean water in the connector plug holes will help the connector slide onto the switch ports.
LOCATING VACUUM LEAKS


WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
  1. Disconnect the vacuum harness connector located between the a/c heater control and the HVAC housing under the instrument panel.
  2. Connect the test set vacuum hose probe to each port in the HVAC housing half of the vacuum harness connector, one port at a time, and pause after each connection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each connection is made. If OK, replace the faulty a/c heater control. If not OK, go to step 3.
  3. Determine the vacuum line color of the vacuum circuit that is leaking. To determine the vacuum line colors, see the Vacuum Circuits chart below. Disconnect and plug the vacuum line from the component (fitting, actuator, valve, switch, or reservoir) on the other end of the leaking circuit. Instrument panel disassembly or removal may be necessary to gain access to some components. Refer to Instrument Panel System for the procedures.
  4. Connect the test set hose or probe to the open end of the leaking circuit. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each connection is made. If OK, replace the faulty disconnected component. If not OK, go to .
  5. To locate a leak in a vacuum line, leave one end of the line plugged and connect the test set hose or probe to the other end of the line. Run your fingers slowly along the line while watching the test set gauge. The vacuum reading will fluctuate when your fingers contact the source of the leak. To repair the vacuum line, cut out the leaking section of the line. Then, insert the loose ends of the line into a suitable length of 3 millimeter (0.125 inch) inside diameter rubber hose.
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