I spent some quality time with my HVAC system again yesterday. I noticed that my center comb flap wasn't working so I took the actator apart. The diaphram was good but when I tried to reassemble I found the reason why it wasn't working. The actuator arm could not attach to the comb flap because the little nipple on the comb flap where the actuator attaches is broken off. It appears that in order to replace this I will need to remove the heater box and dash as well as drill out the rivets that hold the comb to the heater box. Is this correct? Is there an easier way that I am missing?

All help is appreciated.

 

I think that is the case unless there is a "keyhole" type surgery that can be performed.

 

Making the keyhole is how I was finally able to see that the nipple was gone. I spent a couple of hours fishing through the A/C vent behing the glove bx and looking at it with a mirror. I finally gave up and drilled a hole in the front of the box with a hole saw and found the problem. I can't see a way to fix the nipple through that hole unless I were to glue it. I don't know if that will hold.

 

It may be worth a try using super glue or some other adhesive as the alternative is not so exciting 8>(

 

I'd try to create a new nipple on a small rectangle of plastic and spread some really strong epoxy like JB weld etc. on the back side of the rectangle after attaching the piece to the actuator so I could slide the whole assembly in place and try to 'stick' the new piece to the spot where the old nipple was...maybe some really long forceps to clamp it while it dries.