Ok, I know your aren't going to believe this, but I'm not showing you everything that I'm doing to the cabin's HVAC.
There's a lot of tedious stuff with this part, and craploads of plastic ducting that needs to be stripped down and washed and bleached (I stopped with the dishwasher because some of the thinner plastic I don't think would handle the heat). What i do with each section is to simply wash it with hot water and dawn, i dump the dirty water and refill with a cup of bleach and dawn to go after the details. Then rinse, check for any remaining slime and dry.
The last pictures I'll show you will be of the upper plenum and the defrost ducting. Ford used staples to hold several of the plastic parts together. They're a little bit of a pita to take out. I didn't take the ones out of the ducting that lead to the vents on the far right and left of the dash. My arm fit into those without too much scraping of skin from my hands and arms. They just got a thorough scrubbing and bleaching to disinfect them.
Upper Plenum assembled.
Starting the tear down.
Blend door out with foam removed. I'll get rid of the glue with laquer thinner.
Defrost vent tore down. I had to tear this down since the inner ducting is so complex.
All clean.
This is the stuff I cleaned this weekend.
LMR doesn't have any heater fans in stock, so I went to Oreilly's. They had to order one out of OKC, it'll be here on tuesday. I'm not sure if it'll fit so I'll take the section the holds the fan down there tuesday evening to see if it fits. Hopefully it does, it's only $33 from Oreilly's instead of $45 from LMR (and LMR is the cheapest I found on the web, though I haven't checked Rockauto yet).
So what this all adds up to is that the entire box and ducting is super clean and disinfected now. I'll start to reassemble it tomorrow. I do have a new heater core, a/c condenser, fan resistor, seal kit and will have a new fan soon. That fan is at the rear of the box, I wouldn't care if the old one worked (it doesn't), I would replace it anyhow. The box has to come out to replace it. I don't want to take it out again......
The parts look new, and with the important stuff for the inside, it essentially will be new. I do need to take my little vacuum pump with me to work tomorrow just to check the various actuators. What should be the effective vacuum be? I need to look that up in my service manuals.