Heater Box Rebuild

Here's what you should have:



The plastic deflector is a 8126129.

 

Alright this is moving in the right direction now! I can see that the hole I have in the bottom of my heater box should really be closed off, it is just visible to the right of the airbox drain tube of the last post. That would also mean that the two holes I have (previously circled yellow) are supposed to be there and ALSO have a deflector of some kind attached. I can imagine that deflector will be near impossible to find so may have to fab something.

Last part of my puzzle...should the flap that controls the defrost/heat direction have the same 1/4" foam on it like the fresh/heat flap has?

 

Just a guess - no foam. Leakage at that point does not matter much. If you have heated air, it will all go into the cabin and provide warmth. The other flap is for cold outside air vs. warmer cabin air? There it would matter to heating if cold air leaked in.

 

I have patched and repainted the heater box so I only have the two defrost vents and the two lower heat vents. I will have to start looking for the additional vent piece show by timgr to add at a later date.

 

In the process of repairing the heater in a '74 Cj5. This is the fresh air flap. To replace the gasket I'd have to split the metal part of the flap to install new rubber. Right? Does anyone have a better way of accomplishing this? Any suggestions on the gasket material you've had success with would be appreciated as well. Thanks

 

McMaster-Carr sells many different types and thicknesses of rubber that you could choose from. https://www.mcmaster.com/rubber-sheets/

It's not a service part. In the day, you would need to replace the whole housing to get a new one.

This is the first time I have seen this flap outside the housing. New territory.

 

Yup familiar with McMaster Carr. Wouldn't you know there are different textures or stiffness that's available (what a country). It's a real treat getting the thing apart too. The way I'm seeing it, the metal part needs to come apart in order to install new rubber. Alas , might just purchase a new fresh air box, considering the cost of all the parts to recondition it. I was looking for one of those "gee why didn't I think of that" moments. Thanks, Dave