accuator shaft on the heater is broken off.

Use a Digital Caliper to measure the depth or use a rod with paint to see where it hits inside the duct work.

JRKMotorZ, Thank you but my main problem is that she has AC But NO Heat. The Shaft on the Heater accuator is not only Broken but is missing all together. I need the over all lenght of that Heater accuator shaft to be able to Fab one. The diagrams and plans I have seen Do Not give me the lenght of the shaft. One gentleman has a fix for one using a 40mm cupling But I need the entire lenght. I have nothing to work with but a numb to work with. Can you Help?

On general duct work on vehicles it's a door that opens and closes with a metal rod while the actuator turns in this case a door from the heater core. So if what your saying is the metal rod for the door is broke inside the duct work you'd either have to pull and split the duct work in order to fab a piece or replace the door with one from a salvage yard or dealership. Chrysler's had this issue in the past because the door would seize and the actuator motor would snap the door and rod assembly off. Some people who were tight on funds would find an alternative way to open the door in an unconventional way.

Okay we are talking two differant areas, I`m talking about the Two accuators on the deivers side by your right leg that work together when you change the climate controls from AC to Heat. The top accuator opens the AC and the Bottom one opens the Heater. Now with saying that, the Bottom Heater accuator shaft which is plastic is twisted off and I guess has been thrown away. Thats the shaft I have to Fab which I can and epoxy it in But my only problem is I need to know the Lenght of the entire Shaft.

Yeah, it's almost impossible for anyone to know the shaft length on them. People at dealerships aren't probably going to know because everything is sold as an assembly and all they have is part numbers. Unless you have access to another Cobalt to measure the shaft whether at a local salvage yard that would let you cut into the duct work and measure the shaft. Otherwise unfortunately it is a guessing game.

There's a bazillion of these cars in every wrecking yard in North America. Why wouldn't you simply go and buy a used part. I know you're o a tight budget but I can't imagine a used one would be very expensive.. Or find someone who is parting one out privately. There's a basillion of those too and for sure the part will be cheap because there's almost nobody who would need one. Way quicker and easier than trying to make one, and your friend can have heat now when she needs it instead of in the spring when she doesn't.