It's a PITA but it only happens once in Vanagon ownership period.
#1) Replace the fresh air/ heater blower.
#2) Replace the vacuum booster
Those are the only two things that need the dash pulled.
From experience I'd say it might take 6 hours for the R&R process.

Stan Wilder
Engine Ceramics
214-352-4931
www.engineceramics.com
----- Original Message -----
From: "Ed" <eduntz@HOTMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, August 23, 2005 2:14 PM
Subject: Hacking up the heater box

OK, I still can't find the article on replaceing the front heater fan
without removing the whole dash. (I know it's out there, though, and at
least one person has done it.) But I think I'm remembering bits and pieces
of it. I think the person who wrote it used a Dremel to cut open a portion
of the heater box to get at the van, and then glued it back together. Does
anyone who has done the replacement think that this might be workable, even
if it is a bit of a hack?

Ed