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Originally Posted by xeroinfinity
Well I'd personaly try fixing the chunks without removing the entire box.
It would be 4-6 hrs to pull the whole thing out.
So it is the back half of the case thats broke ??
If it is just the front cover go to a salvage yard and pic one up.
I'd silicone around the two halfs.
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Yeah, it's the back half, the upper strap was missing too (probably because there is no longer anything to screw it to
). I tried duct taping over the holes, and taping the heater core to the box, but it didn't increase the temp very much, only a few degrees. I was going to spread some JB weld over the tape to make it solid, but the tape's still in place and the temperature increase was almost non-existant, so I'm not going to waste two more hours (plus dry time) taking it apart again to try it.
I'm going off memory here, so I may be a bit off. Above and to the front of the heater core there is a door. I believe it's the temp blend door. I thought the opening needed to be partially blocked off (doesn't look like it seals on the back(?) side), but a co-worker said that they're all completely open. I've done dozens of these heater cores, and don't recall ever seeing that open before. He's been a technician 3x longer than me, so I just assumed he was right. Do you know what it should be like? I'll try to get a picture of it, my memory is hazy sometimes, and my descriptions aren't always great.