MAGK944

As the title says the dash is coming out in a few weeks. What other things should I do while I'm in there?

I have ordered most of the plastic clips that are visible from under the dash, heater, evaporator clips, etc. What about any rubber parts or the a/c expansion valve? This is a FL car so most of the rubber and plastic will be brittle or deteriorated. Any electrical solenoids/wiring under there that I should look out for? Thx

RedRose

dash lighting.

VWaddict

Wait... Instrumentation lighting? -The "dash" doesn't have to come out for that, just the instrument cluster.

In my car, the main air distribution plenum won't send air to the windshield... The dash would have to come out to do that, but since my dash is perfect, and I'm more likely to mess something up, I'm just living life without defrost...

MAGK944

Instrument lights done a while ago. I'll be checking the air ducts and have duct tape to reattach them to the vents. I think some of them have popped off during the years.

How bad is the insulation likely to look around the heater and evaporator cores? I am dreading that it will crumble to powder. Worth spraying some foam in there?

DarylJ

Don't use duct tape. Use at least aluminum tape, or a good automative fabric tape made for the purpose if you can get your hands on it. Duct tape will last maybe a year, tops. And no matter what you use, it's like paint - prep, prep, prep, and clean some more before putting it on. The more prep you do, the longer it will last.

And yeah....it's really likely that you will find all of the insulation crumbled. You don't want to use expanding foam because it hardens. As you drive it will crack (and maybe even squeak/crunch) as components move. Find some high density foam to cut and fit instead.

aj986s

With the dash out would be a very good time to assess the heating and AC components. Great opportunity to maybe get a non-working AC working again.

MAGK944

My AC works but not blowing cold enough or through all of the vents. I am going to swap out the expansion valve as I think it's original and a pain to get to on an 86 without removing the dash. Will also swap out any seals in there to 134 compatible, I did the conversion some time ago and didn't replace the under dash seals.

What about electrical stuff, there seems to be a lot of solenoids, relays, microswitches under there. Should I just buy a bunch and replace - I don't want to get back in there a few months later. Anyone got a list of parts they replaced when they did the dash?

DSMblue

I would seriously consider taking all air distribution hoses out and running them through a dishwasher cycle to get rid of 20+ years of dust, etc. as well as cleaning any areas relating to it, such as the evaporator housing. I need to do this, just haven't put together time and energy for how long the car would be down.

plumbum

The foam around the HVAC doors on my car were in bad shape. I also cleaned a few grounds that were easy to reach with the dash out of the car.

MAGK944

Yes, I know some of that foam stuff in there is bad, Ive seen it come flying out the vents and found pieces on the floor over the years.

Is there a recommended foam to use or do I just buy any high density foam?

Grounds! Almost forgot, thanks for the reminder. I'm taking the opportunity to also have the windscreen replaced. It has some chips and a small crack. It will be removed and then fitted back after the dash is back in place. So I'll have factory access to everything under the dash

Will post pics and writeup as I'm going along. Just been notified by Rob at 928leathershop that the new dash kit is on it's way!

Grandpa#3

After the dash is pulled you have easy access to the heater flap doors. The doors will have crumbled foam around the edge. I went to Lowe's and bought Felt Door Weather Stripping, cut and shaped it to fit the door flaps for a good seal, "Not too Tight". I added epoxy to the inside edge of the felt as I did not trust the self adhesive to last on the back side of the tape. The rectangular opening for the center air vent also needs weather stripping applied around it. The center dash and both end movable vents have a narrow opening that I filled with a folded thin felt to fit down into and applied regular glue. Now when I close the vents the air is directed where I want it to be. On the Air Handler I replaced all the vacuum lines on the passenger side as these lines actuate the Flap Doors.

http://www.clarks-garage.com/shop-manual/hvac-03.htm

http://www.clarks-garage.com/shop-manual/hvac-01.htm

Cheers,
Larry

Olli Snellman

You can do this while you're there







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FRporscheman

Just when I thought I'd done everything to my car... that is a clean looking heater box.