Quote:
Originally Posted by auBoxster
Any reason you didn't try the hack whereby you remove (drill / grind etc) the top of the heater box to expose the top plug of the flap axis? You can then just reach into the front section of the heater box and remove the flap. Relatively speaking, not much needs to be removed, and you just re-install the flap and cover the plug with tape or a bit of tin metal fastened down etc... works a treat... !!
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I did consider it but I don't understand the procedure and didn't want to cut the heater box. I did cut the heater box on a 97 Ford Explorer for a similar issue and it worked great so I can see something like that works. The top of the heater box is not easily accessible. It's under the dash, and from the frunk side, behind the firewall. Even with the dash removed its buried (see the pics below) The only time I saw the top of the heater box was when it was out of the car or from the heater core area in the frunk. A DIY on that with pics on that would be great as another option.