https://www.dieseltruckresource.com/...s-t170393.html

i am sure we have all read that, either with fear and loathing that ours may break, or after it breaks, with fear & loathing at the cost & complication of the fix.

So i paid a buddy to do mine, he's a semi-retired mechanic. I let him keep the truck several days and did not rush him, had him do all the Heater Treater doors.

since mine was a Mega, there was some PLO when we were done (Parts Left Over)

and it worked GREAT for about six months.


after while, the defrost/feet door quit again.

i lived with it until it was ~29 this morning, and the heat fried our eyeballs trying to get our feet unfroze on the way to work.


so i looked at the Heater Treater directions, and the def/feet motor is behind the center console bulkhead.

armed with that info, i decided to either:
-fix it
-break it worse
-trade it for a FeRD.

I ended up cutting down the stanchion/pedestal that the 3 screws screw into.
i cut them down the size of the white teflon bushing, and just mounted the motor so it's teeth fit in the heater treater bushing.



here's all the pics
http://s19.photobucket.com/albums/b1...VAC/?start=all



and here are some highlights:





29 degrees was too cold to worry about being neat. I paid $40k for the truck, $250 for the HT doors, and $500 for labor the first time.
i don't GIVE A FLYING CRAP what it looks like now. i just want the hvac to WORk





you can see the white part I took out from the gas pedal area:






heres the little white Nubbin that shredded itself.





here's the interface with the HT door drive mechanism: