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I removed the heater/blower from my non AC parts truck to install in my formerly AC truck. While I had it out I installed a new blower motor and heater core. There was quite a gap between the heater core and the end of the core oposite the in and out tubes and the blower box. It seemed odd at the time but I put it together anyway. Both cores looked the same. Today I installed the blower in the truck and it seems that all I get is luke warm air. Is there some kind of a spacer that should have been in there to make the air go through the heater core?
There should be a dense foam cushion on 3 sides of the core. It fits around the top, bottom and passenger side of the core. Without it air can pass around the core instead of thru it. Many times this foam is in pretty bad shape and may have been thrown away by someone that changed the core. As far as I know they are not being reproduced, yet.
Another possibility is your engine does not run hot enough to produce much heat. My 460 is that way and in the winter I have to block off part of the radiator to get enough heat and I live in Texas where the winters are pretty mild. And yes I have a 190 degree thermostat.
I converted my heater box to fit the high output heater core (was actually cheaper, too!) It involved splitting the plenum and removing the 'lifting block' piece of plastic with a dremel. I then assembled everything using a couple layers of that foam weatherstrip tape around the core. I have the most incredible heat! Even the last time I drove it, when it was -35 degrees C, and I was happy as a clam inside. (roads were closed due to an ice storm the night before, but with the trac-lok rear diff, I had no trouble!)
Dang, I miss my truck....
It turns out the problem was both of the issues LTAR talked about. I think I have a bad thermostat. I blocked over 3/4's of the radiator off and was able to get the gauge up to just below normal, and was able to get ok heat. Next week it's new t'stat time.
You should never need to block any part of the radiator with cardboard to get heat. There is a problem with the cooling system. Check simple things like coolant and water ratio. Before I install a thermostat in any vehicle I first check it on the stove in a pot of water with a candy thermometer to see which temperature it opens. It sounds like a lot of work. It's better than finding out the $5.00 part is faulty after it's installed. I once had three bad thermostats in a row. Just hang the thermostat so it is off of the bottom of the pot to get an accurate reading. Another cheap and simple part to check is the often overlooked radiator cap.
Your problem may be in the heater hose, Be sure that your heater hose, if it has the garden hose style turn off (or other style turn off valve) that you have that open to allow the water to flow. It could have an air gap in it also, and not circulating.
This is something I have noticed on A/C trucks. and most people turn it off in the summer when running the A/C
Quick update.
I installed a new thermostat and it made a world of difference. It turns out that Cummins only makes one thermostat for my engine, and my choice of temperatures was 180*. I had hoped to get in the 190* range but no go. My heater is plenty warm now, but we will see when it gets down in the -30* range in a few months. If it is too cold I will add the cardboard thermostat back in.