Good Evening Everyone,

 

I'm new to the site but have been reading up on some great articles and opinions for some time now.  I'm in the process of updating and replacing the heater core and AC guts under the dash, along with a new LMC dash top (yeah i know, everyone's wallet just cringed a little).  For all but a short time, I know how its been taken care of since new.  So, i'm willing to replace whats needed and upgrade what should be.  The AC has been leaking in there for some time and i figured a new heater core is just common sense when everything is apart.  My questions are, has anyone needed to replace the blend doors due to breakage (age, not mishaps with stuff getting in the heater box), or thought it a good idea to replace the plastic parts with metal or aluminum?  I know the blend door motor connector is a big one, but what about the other components?  I'm not looking to pick winners or losers of suppliers but Blend Door USA seems to offer a well made kit for the second gens.  At $325, its not cheap but may save pulling the dash later on.  I'm having it done (time and ability constraints) but I know the factory foam will be brittle and dirty at the least.  I say this as I haven't seem them out just yet but foam bits are blowing out of the vent doors.

 

This is the big project for now and i'd like it to be a "one and done" job.  Any thoughts or experience is a great help!!  I know 3rd gens seem to have this trouble worse, but i would imagine a rig almost 20 years old can be expected to need this attention at some point.

 

The next thing is possibly a fuel pressure gauge to see how my dealer conversion lift pump is doing......may not want to know!!

Yup. Most just hit the local Home Depot for the foam.

Thars where mine came from.

Hey, just thought I'd give an update to the blend door/HVAC overhaul.  Sorry, no pics of the tear down.

 

The evaporator had a small leak and some minor buildup.  Not bad considering I had been topping up yearly until the last charge lasted 3 weeks before blowing warm.  The heater core was in good shape but for a super small rust spot, never leaked coolant into the cab.  That was a surprise that it didn't leak, but also that it rusted as the coolant gets changed ahead of schedule.  The LMC dash top went in and fit well, the mist grey color match was spot on.  I recommend getting the dash reinforcement kit as well, sure can't hurt.  Purchased mine through Walking J Designs, great customer service too.  The LMC instrument panel cover was also OEM looking.

 

The blend doors were....well....nasty.  They copped some pretty good amounts of construction dust and cigarette smoke for a short time.  That and age took a toll.  Having already purchased the Blend Door USA kit before seeing them was just as well.  The kit went in great and functions as it did.  I will say for anyone thinking of this kit, one of the OEM doors has a spring door attached (you'll see in the pics).  The replacement door doesn't have this.  After speaking with someone from Blend Door, he said it wasn't possible to reproduce this function, but wouldn't affect the function as only a small amount of air gets redirected to the defrost vents when only floor vents are selected on the switch.  I can't say as i ever noticed.  Big thanks to them for answering my questions last minute!!

 

The new doors went in great and function just like new.  OEM doors are still available but are more expensive (at time of purchase) than the Blend Door kit.  Ironically, the OEM plastic interposer was still in great shape, not even starting to show cracking.  I still used the replacement aluminum unit from the kit.

 

Great to have A/C again and the dash not cracked up!!  Big thanks to the fellas up in Floyd Va. at the Dodge dealer as well!!  I would suggest checking your radiator hoses, thermostat, and antifreeze as this is a great time to service those while spreading parts around the shop!!