HVAC Plenum issues

[Flyman 27]

Has anyone removed their complete plenum? Not just the heater core, but the housing the heater core mounts to?
I have to replace a locked up Blend Door Actuator which requires the entire plenum to be removed. I just can't quite get it. If anyone has some input, it would be greatly appreciated.

Dan

[WARP TEN]

Has anyone removed their complete plenum? Not just the heater core, but the housing the heater core mounts to?
I have to replace a locked up Blend Door Actuator which requires the entire plenum to be removed. I just can't quite get it. If anyone has some input, it would be greatly appreciated.

Dan

Hey Dan--I am pretty sure Marc and Bob Haibeck have done a fair amount of that kind of work. Maybe a good idea to talk with them about how to do it. And maybe an even better idea to send it to them for the work. That's what I would do. It is not a fun job as I understand it. Anyway give them a call and at least they could tell you about the job and quote a price. Good luck with it. --Bob

[Flyman 27]

The car is not able to go anywhere right now. It is not at all drive-able.
The dash is really torn apart, lots of work needed in there.
The plenum is apart & the heater core are out. The heater core I replaced a year or so ago was leaking (thanks China). This time I have an OEM heater core to install!
I just can't figure out how to remove the forward half of the HVAC plenum.

[Flyman 27]

I GOT IT!!!
You have to remove the evaporator and both sides of the evap plenum. Not an easy task.
Some of the evap plenum attachments are dual purpose. They are studs mounted to the HVAC plenum, go thru the firewall & attach the Evap plenum.
The HVAC front section is sealed to the firewall by some really sticky sealing tape, don't know how I am going to try to figure out how to reseal it.
But, I can access the blend door actuator now!!!
I didn't want to redo this job again.... So I hunted down a NOS Blend Door Actuator. None of that Chinese crap parts.
Tomorrow it starts going back together!

[Flyman 27]

This was quite a project, this is how far the car had to be torn down to get to the Blend Door Actuator. Now I hope I can remember how to put it all back together now. It took about 7 hours to get this far. The under-dash wiring was a mess. It took maybe 30 zip ties to get it cleaned up this far.

[ghlkal]

What a job!


Thanks for posting your results and the pics.