Blend Door swap non hack way?

[GamingKing]

Hi i got a 97 stx 5 spd and the broken blend door that everyone gets is getting fixed finally. I was wondering if anyone here can help with the last part of the fix. Im trying to replace the door without cutting a hole in the box like all the videos on youtube show and even with the doorman instructions say. I removed the dash enough to remove the entire heater box and now that its out i cant see any way to separate the box to install the new door. Theres little snap tabs all the way around but i think the box is glued from the factory. Can anyone confirm that or is there just a trick Im missing?

 

[mfernandes]

I can help you my friend.
I bought a complete uderdash hvac plenum chamber for my truck and I will be replacing the original one in a couple of months.

My plan is to take the dash out, remove the original plenum and reinstall this one, with a new heater core, new blend door and blend door actuator.

I couldnt figure out how to separate both lower and uper part of the plenum (if you did please let me know how you did it). So, from the big square hole from the back (where it meets the a/c evaporator) remove the original blend door.
The new Dorman blend door has an aluminium head which comes off. You cant place this new door whithout removing this aluminium head.

So, once removed (just pull this head and it will detach from the blend door axle), tilt the new door till it fits in the bottom hole of the a/c plenum, put the aluminium head back again on the top and rotate it till it snaps on the upper hole.

If Im not clear, I can shoot a couple of pics. I have to clean everything inside this chamber before assembling everything back.

PLEASE, IF YOU FOUND A WAY OF SEPARATING THE A/C PLENUM LET ME KNOW. I couldnt figure it out!!

Hope this helps, let me know if I was not totaly clear man!!!