I did quite extensive research on this forum as well as Youtube (Froggy, etc.) on how to replace this switch. Here is what I found that could be helpful to others.

1. Driver's knee bolster has to come off. At this point, I would try to see if the switch will easily be pushed out (i.e., maybe its already loose or the tabs are broken. You can also try placing a screwdriver on the switch and hitting it pretty hard once or twice to see if it will come loose. Mine did not. If it wont come out easily, go to step 2.)

2. Center console and radio has to come out. I know there are people out there that say you can simply just reach up through the knee bolster and push the bottom tab on the switch. However, this i nearly impossible. Its actually quite difficult to even get your hand on the switch let alone depress the bottom tab. And its nearly impossible to get a screw driver up there to depress the bottom tab. I tried for about an hour before giving up.

3. To get the switch out, is a TWO person job. One person reaches up through the radio with a screwdriver to depress the bottom tab and the other person takes another flat head screwdriver placed at the top of the switch and hits the butt of the screwdriver fairly firmly. The switch will come out. To install the new switch one person slides it up near the hole and the other person grabs it will needle nose pliers aligning it. Then push in firmly from behind. I tried this method a few times on the old switch to knock it loose and it worked every time with no issues.

Some people say that you can get a thin screwdriver in from the front on the top to depress the top tab. I tried this for quite a while. First, you will damage the vent surround and second its difficult to get enough leverage to depress the tab downward. This is worth trying but I had absolutely no luck with this method.

 

Tried posting some pictures. but doesn't seem to be working. Sorry. I will try again,

 

Frankly, it’s a lot easier to just pull the dash pad. It’s only difficult the first time, and then you’re ready when you need to do it again.
And if you don’t think you’ll ever need to go back in, you’re not reading the threads on blend door actuators.

 

removing the entire dash is easier than taking out the radio and surrounding bezel!?? You must be very fast and efficient at removing the dash. I avoid doing that like the plague! haha. I have only had to replace my drivers side actuator and I did that without removing the dash. Fortunately, the passenger side actuator hasn't had any issues (which actually I believe that they more often than not never do.)

Happy Motoring

 

Loosening the dash pad isn't too big of a deal. You just need to raise it enough to get your hand back there...you don't need to pull it completely out

 

that is true. I still had a problem getting the tabs depressed simply by hand let alone two of them though. a screw driver was necessary to get a tab depressed enough to get the switch to loosen. There are probably many different ways to do this replacement. for me, this was the easiest and fastest.

Remember, Happy Motoring

 

You're a lucky guy if all you've needed to replace is one actuator!!! On my 2000, most of them are bad. Gonna have to do something soon. Since my A/C Evap is also leaking, it's not gonna be a cheap fix...

 

yeah, I have never taken the dash out but according to the post above its not that difficult.

Im not sure what else is involved after that to get to the evaporator. but I imagine the dash is most of the battle.

 

From my understanding, virtually everything in the front of the interior must be removed, sadly....

 

In 2023 there doesn't seem to be anything that has not only already been done, but already been done with video documentation:

 

Hope everything goes well! Please post some pics along the way. Im curious how the repair goes. Happy motoring

 

Yeah, Im def not removing the dash and motor to get to the hazard switch! Happy motoring, sir!

 

Yeah, reply was intended for Grinder11 noting his evaporator is leaking. Not a task I would undertake lightly. Pretty sure Bill Curlee has a tutorial here somewhere, but don't find it right off.

 

I still would not remove the entire motor to get to the evap.

happy motoring.