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I thought I would let others know that I bought a blend door from a website called heatertreater.net. They sell a replacement door and detailed instructions on replacing it via cutting an access hole through the plastic behind the glove box and then cutting another hole in the heater plenum using a dremel tool.
The whole job took less than two hours and worked great. I was a little worried about "butchering" the back of the glove box and plenum, but it's a 13 year old truck so I thought worth a try. None of the cuts are visable. They provided the dremmel bit and some real strong metalic tape to reseal the plenum. I really didn't want to go through the hassel of removing the dash.
My truck is a '97 F150 4X4. They have blend doors for many makes and models.
Anyways, I would reccomend this as an alternative to removing the dash if your only prob is the blend door. Worked very well for me.
I'd heard about that heatertreater. But regardless of the age of the truck, you're still cutting into the dash; something I couldn't force myself to do.
Again, the cuts are on non-structural trim pieces behind the glove box. Barely visable with the glove box open, and only if you try hard to look for it. I was way more uncomfortable with removing the plastic dash in this cold weather.
To each his own. Just telling others that it worked for me and was very easy. I have no concerns about rattles or any other related probs. Of course, if the heater core does go bad some day I'll have to remove the dash anyway. I'll burn that bridge when I get to it.
Pretty happy about my quick fix and to have heat again.
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