Since I bought the truck 5 years ago or so I have been dealing with poor air flow from the heater and A/C.  In fact, it struggles to keep the windshield defrosted, especially with several people in the truck.  Once in a while, usually after start up, I get a faint smell of something burning and I have even had smoke come from the vents a couple of times.  The problem has been getting worse so I finally decided to pull the HVAC box and found what I thought I would.  The evaporator is caked in leaves and other debris.  I looked all over for where the burning was coming from and the only thing that I can see is that the blower resistor was covered in the same debris.  With the resistor broke the conductors on the inside are exposed and I assume that they have been the cause of burning.  There is nothing burnt or charred inside the box. 

 

How do I keep this stuff from getting inside the box again? 

 

I ordered a new heather core, evaporator, resistor, and blower since it is getting tough to spin.  It ought to be much better than it was once I get it back together. 

Genos, I think, carries a filter you can install over the cowl or you can remove the cowl and add some screen to help keep it out. I personally have not done either but other members here have. I am sure they will be along.

2 hours ago, dripley said:

Genos, I think, carries a filter you can install over the cowl...

 

Yes, they do and it is a worthwhile investment.  The filters are washable, as well.   I did my HVAC repairs one year ago and I did not want anything to be able to work its way into the ducts. 

 

I also installed a coarse screen over the inlet part of the upper fan housing.   The screen fits around a removable part that can be accessed with the heater fan removed.  If you don't do the Geno's cabin filter, at least add the coarse screen.

 

- John

Motor is overheating from bad bearings and blew the resistor. Typically it is the blower motor to blame.

I didn't want that goofy looking cover for vents so I just did this. I was also able to vacuum most of crap out with a rubber hose, flash light and a mirror. It was uncomfortable at times under the dash but I did it. 

I can't believe I waited this long until I pulled the HVAC box and cleaned it up.  It is all back together and it is nighty & day difference.  I was reluctant about pulling the dash back to access everything but it really was pretty straight forward.  The only problem that I ran into was the new blower didn't come with the weather tape inside like the OE blower had.  I didn't realize this until everything was installed and I turned it on.  Without that weather tape, it didn't sit tight and vibrated which made an odd sound.  I pulled it and put in foam striping and it sits great now, no vibration or annoying sounds.