Rogue Heater Fix Instruction Manual

1. Safety and Preparation

Before installing your Rogue Heater Fix™ Repair Kit, familiarize yourself with these instructions and related procedures listed in the factory service manual (FSM). Refer to the FSM for additional troubleshooting or questions. Do not violate or modify procedures listed in the FSM, and follow all safety guidelines therein.

1. Use safety equipment including, but not limited to: safety glasses, gloves, protective clothing, etc. Tools should be in good working order. Suggested tools are shown in figure 
2. Lay out supplies provided in the repair kit to ensure no parts are missing. Make sure your work area is clean, safe, and has adequate lighting.
3. Only use the high quality, plastic-safe grease provided in this kit. Other types of grease may degrade the plastic or compromise structural properties. Follow all safety guidelines on any chemicals or products provided in this kit.
4. Disconnect the battery negative cable from the battery.

Disclaimer:
Be aware of the physical requirements for certain steps in this repair procedure, and use necessary caution. Renegade Solutions Company is not liable for injuries obtained related to this repair. If in doubt about your mechanical ability, hire a professional.

You can watch the video instruction here:

2. Panel Removal

NOTE: Suggested tools are pictured in figure 1.

2.1. REMOVE instrument panel side finisher by prying out to release the retaining clips.

2.2. REMOVE center console side finisher.

2.2.1. PULL straight out to release the retaining clips.

2.3. REMOVE instrument lower panel.

2.3.1. REMOVE the two bolts at hood release cable.

2.3.2. REMOVE OBD connector and accessory connector (if present) at release tabs using a suitable tool.

2.4. PULL out on panel to release clips.

2.5. Using release tabs, DISCONNECT electrical harness connectors (figures 3–6).

3. Front Foot Duct-Vent Removal

NOTE 1: A 90 degree pick may be used to unfasten the vent after the screws are removed. The vent can also be rotated and removed.

TIP: The screws are hard to reach. A micro ratchet OR a #2 Phillips bit taped to a quarter inch wrench works well (figure 1).

3.1. REMOVE front foot duct-vent by removing the two screws (figures 7–8).

4. Blend Door Motor Removal

CAUTION

Damage to the connector or motor can occur if excessive force is used.
The blend door motor electrical connector will come apart easily when done correctly. No force is needed.

4.1. REMOVE left-hand blend door motor using these steps:

4.1.1. REMOVE the two attachment screws to unfasten blend door motor from heater box (figure 9).

4.1.2. DISCONNECT electrical connector by prying against release tab using a small flat blade screwdriver (figure 10).

5. Parts Cleaning

NOTE 1: See figure 11 to locate heater door bore.

NOTE 2: Use ONLY brake cleaner or rubbing alcohol for cleaning. These cleaners leave no residue and will not damage the plastic. The cleaner the bore is, the stronger the repair will be. Only one attempt may be possible on the heater box so be thorough. Use a cotton swab if needed, along with little cotton balls.

NOTE 3: Parts MUST be completely dry after this step.

5.1. BREAK cotton ball into 3 or more pieces.

5.2. Using piece of cotton ball and tweezers, WIPE door bore.

5.3. APPLY cleaner to one of the cotton ball pieces.

5.4. Using soaked cotton and tweezers, SCRUB door bore.

5.5. REPEAT steps 5.3-5.4 until cotton comes out clean.

5.6. CLEAN Rogue Heater Fix™ insert using cleaner and cotton balls.

5.7. ALLOW door bore and insert to air dry.

5.8. USE a hair dryer or compressed air to dry parts for one additional minute.

5.9. TEST FIT insert into door bore of heater box.

5.10. ENSURE insert goes in far enough to contact heater box.

5.11. If there are any issues with fitment
THEN CONTACT support renegadesolutionshelp@gmail.com

6. Activator Application

CAUTION

Injury may occur if use and disposal of chemicals, or adhesives used in this repair are not in accordance with the package directions. Abide by state and federal regulations. To avoid skin, eye, respiratory irritation or injury, use safety equipment and work in a well-ventilated area.

Chemicals may be flammable. Keep out of reach of children.

NOTE 1: If the activator cotton is dry it will NOT work.

NOTE 2: See figure 2 for parts/supplies identification.

6.1. APPLY activator to insert and door bore using these steps:

6.1.1. UNSCREW cap from activator vial.

6.1.2. ENSURE cotton in the activator vial is damp.

6.1.3. WET a cotton swab in activator vial by compressing cotton wad inside vial.

6.1.4. WIPE cotton swab against inside neck of vial to remove any free liquid.

6.1.5. REPLACE activator vial cap.

6.1.6. Use swab to COAT activator evenly INSIDE door bore.

6.1.7. Using same swab, WIPE activator onto outside lip of door bore.

6.1.8. Using same swab, WIPE activator onto long hex shaft of insert.

6.1.9. ALLOW all parts to dry 5 minutes before proceeding.

6.1.10. ENSURE step 9 is completed between 5-15 minutes of activator application.

You can watch the video instruction here:

7. Gear Installation and Grease Application

NOTE 1: If any gears or posts fall out of the motor when opened, see figures 14-15 to reassemble it.

7.1. If you have ordered a kit that includes a new preassembled blend door motor, THEN SKIP this step and continue to step 8.

7.2. SEPARATE the two case halves of blend door motor using these steps:

CAUTION

The screwdriver will stop at the correct point if inserted in CENTER of the tab. If inserted on the side of the tab, damage may occur.

7.2.1. SLIDE screwdriver under the center of one tab of blend door motor until it stops.

7.2.2. ROTATE screwdriver 90 degrees so tab is elevated from case of blend door motor.

7.2.3. INSERT a toothpick next to screwdriver and under tab just far enough to hold it up without either letting tab relax or pushing up further.

7.2.4. REMOVE screwdriver.

7.2.5. REPEAT steps on the other 3 tabs.

7.2.6. While tabs are held up by toothpicks, WEDGE screwdriver between case halves of blend door motor to separate them.

7.3. REMOVE and DISCARD factory gear (figure 13).

7.4. Using a cotton swab, APPLY a light coating of grease from kit to new Rogue Heater Fix™ gear, including gear teeth, outside of both hubs, and disk panel at the base of hubs.

7.5. APPLY a light coating of grease to case halves.

7.6. INSERT Rogue Heater Fix™ gear into lower case half.

7.7. If needed, ALIGN parts in lower case half.

7.8. ALIGN case halves and PRESS them together.

8. Heater Box Case Grease Application

NOTE: This step is important as it will prevent any spilled adhesive from adhering to the heater box itself.

8.1. APPLY grease to face of heater box around and up to outside of door bore with a cotton swab.

9. Insert Installation and Adhesion

9.1. ENSURE short hex shaft of insert slides completely into new gear without stopping.

NOTE 1: Depending on humidity or temperature it could be a little tight. This is normal. If gear and insert don’t slide together completely, contact support.

NOTE 2: Also contact support if previous repair attempts have damaged the door bore all the way to the end on the inside.

9.2. INSTALL insert into heater box using these steps:

9.2.1. IMPORTANT: Soak a rag in cleaner and have it nearby.

9.2.2. ASSEMBLE glue needle onto the 1 milliliter syringe provided.

9.2.3. REMOVE syringe plunger by pulling it out.

9.2.4. Using package directions, FILL syringe with adhesive to about 0.5 ml or more while wearing rubber gloves.

9.2.5. INSERT plunger and hold syringe with needle up at about a 45° angle.

9.2.6. PUSH plunger to remove air trapped and bring adhesive level to exactly 0.5 ml.

9.2.7. If glue gets on gloves, THEN CLEAN or REPLACE them immediately.

9.2.8. If glue gets on syringe, THEN CLEAN immediately.

9.2.9. ADD exactly 0.3 ml of adhesive inside door bore with syringe.

9.2.10. Using cleaned screwdriver from kit, SPREAD adhesive evenly inside door bore.

9.2.11. DISCARD screwdriver.

9.2.12. If adhesive leaks onto heater box case, THEN CLEAN it quickly.

9.2.13. APPLY light coat of adhesive to long hex shaft of insert.

9.2.14. ADD less than half of 0.1 ml of adhesive to end of long hex shaft of insert including center vent hole.

9.2.15. INSTALL insert into door bore until it contacts the heater box.

9.2.16. WAIT one minute.

CAUTION

Damage can occur if insert is pulled instead of pushed while wiping or rotating before adhesive has fully cured.

9.2.17. WIPE any excess adhesive from heater box or insert.

9.2.18. ROTATE heater door by turning insert back and forth to ensure it moves freely.

9.3. ALLOW adhesive to cure for a minimum of 24 hours before vehicle is assembled further.

You can watch the video instruction here:

10. Blend Door Motor Installation

10.1. INSTALL blend door motor onto heater box.

10.1.1. GRASP installed insert and rotate heater door by hand.

10.1.1.1. If heater door does NOT rotate freely
THEN CONTACT support.

10.1.2. INSTALL blend door motor onto heater box.

10.1.2.1. If blend door motor does NOT slide into place easily
THEN ROTATE insert slightly and repeat.

10.1.2.2. INSTALL screws.

NOTE: Do not overtighten screws.

11. Front Foot Duct-Vent Installation

11.1. REINSTALL front foot duct-vent and two screws.

TIP: Start the screws by hand before using tools.

12. Panel Installation

12.1. REINSTALL instrument lower panel and both side finishers.

12.1.1. RECONNECT electrical connectors.

12.1.2. SNAP OBD connector into place.

12.1.3. LINE UP clips and PUSH panel into place.

12.1.4. REINSTALL the two bolts holding the hood release lever.

12.2. REINSTALL center console and instrument panel side finishers.

13. Final Steps

13.1. RECONNECT vehicle battery.

13.2. OPERATE vehicle to verify correct operation of heater/AC.

TIP:
The manufacturer provides no recalibration procedure for this vehicle and little technical information about this system. These heater boxes have been repaired with immediate success. A few vehicles did not operate the blend door after repairs and were stuck on hot or cold temperature setting. This is because their computer disabled the temperature switching function due to prior heater box malfunction. In such cases, the negative battery cable was disconnected for 30 minutes. After reconnecting the battery cable, the key was turned on with the engine off for two minutes. The key was then shut off for an additional two minutes before operating the vehicle. This procedure worked to reset the system.