so seems my problem has resurfaced again, did some snooping and discovered that the servo arm has jumped tracks again, this time am finding it super difficult to push the arm back, could you post a picture of the l shaped tool you used.

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Slyfox is refering to one of these right angle screwdrivers.....

Ace 0 in. L Assorted Offset Screwdriver 1 pc.(025OS2C) - Offset Screwdrivers - Ace Hardware

But I prefer one of these, I own several of both type but this one comes with many different bits and it ratchets so you don't have to keep repositioning it while loosening screws and this type works better in tight places where you can only turn the screw a little bit, with the other type if you can't turn a screw at least 1/4 turn it doesn't work to well.

https://www.lowes.com/pd/Kobalt-10-P...yABEgLuGvD_BwE

thanks, though was able to pry it open using a simple sturdy screw driver. as narated in the thread below.

Defrost problem.

My Servo is making noise's again. Last time was about 2 years ago but it went away. I just run up/down the temp cycle's and fan speed's with the inside/outside recirculation and it seems to fix the issue (temporally).
With 205K miles on the truck, it seems to be working so far.

Accidentally pried the recirculating servo "out of gear" or off it's tracks tonight while messing under the dash. Posting here so I can find it to research more tomorrow.

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Pulled glove box out, 4 bolts to get the hidden upper glove box out, 3 nuts to shift the ECM over, and 3 tabs on the two connector plastic piece to get access. Then a right angle Phillips head to get the front bolt on the recirc servo loose. Then I was able to pop the stud back into its guide. Reassemble, done! 20 minutes.

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My notes from my servo replacement project DIY: Replace Servo Sub-Assy


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I just fixed mine. The pin jumped out of the track just like in the pictures from the OP. One note. The entire mechanism seemed really dry. I got the pin back in and the arm hesitated going through its motion. I could not help but wonder if there was some kind of lube in the entire moving mechanism that just wore away or dried out over the last 17 years. So I blasted it with some spray white lithium grease and the whole thing seemed to move a bit better. Just a thought for those of you who run into the same issue and get the arm back in place.

My A/C now can blow air on recirculation again so it is ice cold even above 90 degrees.

I realize this thread is old, but I need some help regarding this same issue with a small difference.
My a/c works fine; floor mode, floor + dash vents, defrost, etc. The problem is that, with the recirculate button on, and even though its indicator light is on, the cold a/c air is not recirculated. The speed of the blower motor does not speed up nor does it get colder quickly in the truck. And, I can smell outdoor odors. I am in Florida and must keep the recirculate on at all times because it is a jungle here.
The posts I've seen here and on YouTube center around the actuator that controls the direction of the air (floor, dash + floor, etc.) and whether or not it heats.
I would greatly appreciate the assistance and, if possible, steps and photos to fix it!

Maybe your post covers the issue I am having with my recirculate? But, there is no "clicking" coming from inside the dash. I have my a/c blowing cold and when I push the recirculate button, its light comes on but it does not recirculate. Is that the same issue you had?

It took me a bit to figure this out, but there are actually three servos that control the a/c and heating. On the left side of the blower set up you have two servos. One controls the vents that you want the air blowing out of. The other is a blend door that mixes the hot air and outside air to give you the temperature you want.

On the right side (in the pics a few posts above yours in this thread) is the recirculation servo. This is on the right side of the blower housing. The fact that you push the button and the light turns on means nothing. The pin on the arm attached to the servo (in the pics above) pops out of the groove of the arm that changes the air from outside to recirculating. This is what you want to check and what popped out on mine. Also look on page one of this thread. There is a picture with a red circle on it that points out the pin and how it pops out. This is what you are fixing.


So go to the right side and use a flat head screwdriver to carefully remove the white plastic frame that covers the servo (see pic above). You will have to pop a couple inserts out. You don't need to remove the wiring attached to it. Just be careful and move it aside enough to see the servo pin and whether it is in the groove like the photo on page one. You can also then push your recirculation button on the dash and see the servo arm actually work. At least if the arm moves you can be sure the servo is still functional. Then see if the pin is out of the groove. If so, CAREFULLY pop it back in the groove and test. Make sure to lube it a bit before putting all the parts back on.

It was a great fix and now my air works like a champ.

I can not thank you enough! I will review those photos and this entire thread. I will try to photograph and post my results as well.

** First Off, My Apologies For This Question **
I'm sorry for posting this question here, but I do not know where else to post it, and my numerous messages to Mods have gone unanswered.
I want to post a new thread for assistance and also a thread to show how to finish a repair on my '05 SR5 this week, but I cannot post a new thread because I get the message in the attachment. As I said, I have sent messages to several of the Mods with no reply.
This forum would be much more helpful if I could Post. Any assistance is apprecaited.

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As the message says, you must have a minimum number of posts (15 IIRC) to start a thread. I assume this is an anti-spam measure.