1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Fresh air/recirc actuator replacement

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by yello_downunder, Mar 24, 2019.

  1. yello_downunder

    yello_downunder Junior Member

    Joined:
    Dec 27, 2018
    9
    5
    0
    Location:
    Texas
    Vehicle:
    2005 Prius
    Model:
    II
    when I have climate control running in my 2005 Prius on recirc during warm weather, I get a mostly continuous clicking noise. I have pulled my dash apart and tracked it down to the recirc actuator that is smushed between the heater box and the blower box, near the top of the dash.

    Question is, how do I get to the actuator? I have pulled just about as much as I can off the dash, but I can't seem to get the lower half of the blower box to come loose. I have the top half of the heater box loose, but can't pull it out because one of the mounts is hooked under the metal dash bar. Has anyone done this before?
     
    yibo829 and SFO like this.
  2. daveyedgar

    daveyedgar Junior Member

    Joined:
    Feb 14, 2019
    9
    4
    0
    Location:
    Tampa
    Vehicle:
    2008 Prius
    Model:
    Two
    did you ever figure out how to fix this?
     
    SFO likes this.
  3. yello_downunder

    yello_downunder Junior Member

    Joined:
    Dec 27, 2018
    9
    5
    0
    Location:
    Texas
    Vehicle:
    2005 Prius
    Model:
    II
    I did actually. My mistake was trying to remove the heater box. Instead of doing that, I found the actuator is held on by three or four screws and then it detaches from the side of the hvac box. I had disassembled about the right amount of the dash to reach it. For anyone reading this, the heater box stays in the car and you remove the actuator (a slim black rectangle) from the side of the header box.

    It fixed half of the problem, but the blend door (hot and cold) actuator was also making noise. This actuator is located on the left side underneath the dash, and there is _just_ enough room to remove it without having to take the dash apart. This youtube video:
    pointed me to some ultra-low profile screwdrivers available on Amazon that are able to reach into the tight space and remove the screws. It took about 10 minutes per screw but it saved hours of disassembly.
     
    SFO likes this.
  4. Solman636

    Solman636 Member

    Joined:
    Aug 28, 2014
    99
    37
    1
    Location:
    Florida Panhandle
    Vehicle:
    2008 Prius
    Model:
    Two
    Is it possible to replace the recirc/fresh actuator without removing dash? Is it near the fresh air filter in box? Part number or video available. My gen 2 makes constant slow tick..tick..tick sound when in recirc but no noise in fresh air mode. But breathing diesel fumes at stop lights has motivated me to pursue repair. On the other hand the flap is working but it just doesn't seem to know when to stop in the recirc mode which I use 90% of the time unless fogging up when fresh needed for a few minutes. I was actually contemplating just adding a switch to the wire that powers the servo to turn it off in that position instead of taking off dash which I have done before and would rather avoid. Or should I ignore the sound since it works anyway?
     
    #4 Solman636, Apr 23, 2023
    Last edited: Apr 23, 2023