Originally Posted by ricksbuells
If you are not careful the dash breaks apart really easy like they are ate up from being exposed to the elements. The blend door and the other vent doors are in a black box behind your glove box.They all have acuator motors on them ,there are 3 of them and you have to remove the dash to get to them .If you are hearing clicking I would say that one is slipping through the gears and not opening.I cut a rectangular hole in my firewall right at the heater core hoses and made a cover from sheet metal that can be removed. The heater core lays flat and is held by 1 screw now I can remove it in 5 min. start to finish.Why can't the factory do this from the start? Hope this helps, it took me alot of time learning the hard way.
Do you have any pictures of the mod you make to the firewall?