I deviate from the firewall to rebuild the A/C Box. What a dirty mess this thing is.
Armed only with this exploded view from the shop manual, I get to work.
I remove the (13) 1/4 inch screws that hold the Evaporator and Blower Upper Case Cover on.
I also remove the (2) 7mm A/C Blower Relay screws.
I remove the 7mm screw that holds the Evap Tube.
With that screw removed, I can move the Evap Tube bracket clock-wise to clear the top cover removal.
I remove the 10mm bolt that holds the A/C Compressor Control Relay bracket and Accumulator.
Here it is with the top cover removed.
The A/C Evaporator just pulls right out.
There's a 5/16 screw that holds the Heater Core Clamp and Ground Strap.
I get the clamp out of the way...
...and pull the Heater Core.
I begin removing the 1/4 screws that hold the multi part case together.
Two here.
Inside the box I remove the Blower Case screws. One on the floor of the box.
One at the top back of the case.
One on the outside of the box near the Air Inlet Valve Door.
With those 1/4 inch screws removed, I cannow pull the Blower Case.
I remove the screws that hold the Hot/Cold Door in place. One at this baffle plate.
One on the other side of the Hot/Cold Door housing.
I mark where the blend door rod snapped into the arm for reference.
Splitting the case apart makes getting the blend door out easier, so I start removing the 1/4 inch screws that hold the last pieces together.
Two more at the bottom of the case.
Now I can split the front and back halves of the case apart.
With the case split apart, the blend door just comes right out.
This clip presses into the bottom of the Blend Door Housing. This is where the bottom of the Heater Core pushes into to hold it.
Finally, I have the A/C Box broken down into 6 pieces. Now I just have to clean this mess.
I move on to restoring the dingy and rather ugly looking firewall.
After years of neglect, it's going to take some work to get this back in shape.
The A/C box looks like 10 pounds of chewed bubble gum. What a dirty mess.
I've been gathering parts over time, to include a new Brake Booster, Heater Core, Evaporator, Blower Motor, A/C Box Seal Kit, and various gaskets.
So you know how these things go, one project leads to another. I end up going all out with this. Notice how the Brake Booster gasket was installed upside down from the factory.
So the Booster and Wiper Motor get pulled....
Then why not pull the Steering Column....
A/C Box comes out easier with no dash... Right??
The A/C Box as a complete unit on the floor.
Finally, the Firewall all stripped down and ready for some well needed TLC. (But maybe that A/C Box needs it first hmmm)
