I know this thread belongs in heating and cooling but I have posted this thread in that forum twice now and have not gotten any responses. I have exhausted all other means. The service manual does not cover it and I can't find any post in the board history. Here is what I need to know - I am getting ready to reinstall the heater box back inside the car but noticed the defroster door doesn't close all the way. It seems to sit about an inch open. When I apply vacuum (via mouth) it seems to function fine and opens up all the way.

Is this door supposed to remain this way to allow some air to constantly be directed upwards to windshield? If so,i don't see the point of having that spongy seal material on the door if it is always open. I would like to have correct before installing it so I am not fiddling under the dash down the road.
Thanks Chris

Assuming here that the car runs...... you might try hooking it all up just lying on the floor and see what actions the door takes. Sometimes things work differently when in their "real" environment. Another thing might be the link from the door to the vacuum motor (diaphragm). Is there a bend or 'shape' to it and if you reversed it end to end would that solve the issue?

Assuming here that the car runs...... you might try hooking it all up just lying on the floor and see what actions the door takes. Sometimes things work differently when in their "real" environment. Another thing might be the link from the door to the vacuum motor (diaphragm). Is there a bend or 'shape' to it and if you reversed it end to end would that solve the issue?

No the hookup linkage is straight. I can't hook it up the car is gutted right now. I can't believe the lack of info regarding these boxes. I guess I'll just install it when I get ready and hope it functions ok.
Thanks Chris