Vent Control Bound - wait there is more!!

[TX82FIAT]

Folks, a couple weeks ago I discovered a leaking heater valve. As a result, I realized the old heater core was also leaking a bit. As a result, I noticed a few rust spots on the floor by the footwells and behind the passenger seat (even a small hole).

So, new heater core, new valve, POR15 floors with a fiberglass patch, installed aluminum backed insulation on floor. Reassembled the heater box slipping new core in from bottom and clipping bottom portion of box on. Then tested the cables to make sure my valve would open and shut, bottom of heater box would open and top of heater box would open. BAM!!! The cable for the vent control on top of the box is bound someplace. I know the cowl area is not rusted because I re-did that a couple months ago. Also, the cable was working because two weeks ago I was able to get fresh air into the cabin using that lever.

So, Any quick thoughts? I was planning on unscrewing the pipes from the firewall and dropping the heater core again to see if this somehow unbinds the cable. The cable moves freely in its housing and the door is not stuck shut? Gosh darn a simple coolant drip is turning into one of those never ending problem solution sessions. I even ordered new carpet since the old carpet was coolant drenched as well as 15 years old.

Thanks for any ideas you might have.

[azruss]

just to be clear, you are talking about the lever closest to the driver...the fresh air lever. I have had that jump off the door hook and jam. would need to pull the cowling to check that. If it is the far lever, then i have seen the bottom door open too far and jam trying to close again.

[TX82FIAT]

Yes Sir, Fresh air lever closest to the driver. Guess it wont hurt to pull the cowl again. I'll put some tape down to make sure no scratches. My guess is when i was twiting the lower half of the box I distored/jammed something. I'll take a closer look over the weekend if time permits.

[vandor]

Yes Sir, Fresh air lever closest to the driver. Guess it wont hurt to pull the cowl again. ...

I'd do that before dropping the heater box.

[TX82FIAT]

Csaba, thanks... just pulled off the cowl and moved the air flap on top of the heater box a few times and the cable is now working. Just a little jamb and does not appear to have anything to do with replacing the heater core. Lubed the hinge point and made sure the cable is moving fine. A little WD 40 in the cable case as much as possible. Carpet should be in on Tuesday. I'll hook up the hoses and bleed the system tomorow.