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I am working on installing my aftermarket a/c kit in my 78. When I got the dash off (finally), I saw a gap about 1 1/2" -2" at the area where the upper defrost vents funnel in to the main box. Obviously should not be there as the heat will just vent straight in to under the dash. My question is, has anyone else experienced this? If so, how did you rectify the problem? I can not see how it can reattach back in to the box. There are two, inch wide tabs that are offset from each other that looks like it goes around the wall of the box, but again, can see no way to reattach. My best guess is I'm going to have to build up some foam to fill the gap. Just seems like a bandaid. I would like to have it repaired properly. Thanks for you help.
Sounds like you're missing basic p/n 18547 in the diagram. Click on the link to see a illustration from the Ford parts catalog.
Gasket, heater/defroster nozzle
D5TZ-18547-A
This is listed in the catalog for 75-76 but the same nozzle and housing are used from 73-up so I don't see why it wouldn't fit a '78.
Green Sales, Cincinnati, OH has 1 (800) 543-4959
Dennis Carpenter Obsolete, Concord, NC has 1 (704) 786-8139