Only 1 temp setting: HOT!!!

[epipete]

James,

I hate to say this but, as you already know, you've got a real problem!

If memory serves then the rod travels diagonally from the front right of the heater unit to the rear left, where it slots into a cam that transfers the forward backward movement of the rod into rotational movement of a further rod, this 2nd rod rises from the rear left bottom of the heater unit to the top left where the rotational force operates the flaps!

In a Uk car, by emulating the stetchy guy from the Fantastic Four, it is possible to access the screw that holds the cam on to this 2nd rod, slacken it off and release it, which allows enough play to refit the 1st rod and the replace the cam and Bingo job done! In your US car I fear that even were you blessed with the phyisicality of a squid you're not going to manage that!!!

So I fear that you may need to turn your mind to the notion of removing the entire dashboard to gain access. If you decide that this is the only way and need some help then shout, mines been in and out more times than the, er, hokey cokey!!!

Pete

[GoM100Go]

Update: After some researching and calls to specially shops for advise. It's appears I will not have to remove much. With an endoscopic/boroscopic camera I should be able to endoscopically reattach it using long nosed pliers. I will post how it goes in a couple weeks. We have had an unexpected freeze, so my heater has been running great. Below I have posted the camera and pliers I have cheaply purchased and will be using for the project. Wish me luck!

http://www.ebay.com/itm/280776091370?ss ... 941wt_1191

http://www.ebay.com/itm/5-Pcs-11-Long-N ... 3382wt_871

-James

[epipete]

Good luck, at least if it fails you'll be equipped to go in to Medical Practice! Let us know how it goes.

[tigerdog]

A strange/surprising thing is all the blanks on the dash next to the hazard and ac switch have wired harnesses behind them -for what or leading to what- I have no idea?

Rear fog light was offered in some markets - that went into one of the blanks. Can't remember the other but you'll find it in the Electrical manual. I'm not at home so I can't look it up.
As for the heat, I suppose you could install a manual valve on the hose leading to the core and physically block the coolant flow. Not ideal but better than roasting.

[GoM100Go]

Well today I have resolved the problem, the camera was totally necesary. The best part is that once I looked around inside the compartment. I was able to find the the clip and reinsert the rod, but it was just as I was told at the beginning. It was not even necessary to remove anything. I simply pealed the carpet corner back from under the glovebox and there it was the rod and clip. I used a hook made from a wire hanger and simply reached in guided the rod and used a chopstick to snap the clip closed - 20 min max. If I didnt have the LED lite camera I would have never known how simple a procedure it was you cannot see anything under and behind the consol. Now I can focus on the alarm, stereo and ac... Thanks to everyone for the dialogue. it's so nice to have cool fresh air pumping through the vents on the freeway with the windows up.