In a message dated 8/23/05 3:21:05 PM, eduntz@HOTMAIL.COM writes:

<< Does anyone who has done the replacement think that this might be
workable, even if it is a bit of a hack? >>

Ed,

I just looked at a renewed heater box that I have squirreled (now, ain't that
a helluva word) away.  I did not pop it apart because it is in a state of
sealed perfection.  From what I could determine, it MIGHT be possible to gut it
IF you can slice through the top cover on either side of the motor blister
WITHOUT cutting into the motor housing or the damper shaft and IF you can remove
the two screws on the centerline of the top cover, especially the one toward
the front of the van.  BUT, you're a better man than I am, Gunga Din, IF you can
swing a die grinder to make the cuts with the thing under the dash.  In fact,
even with the heater box on a workbench it would be risky craftsmanship at
best.

Do yourself a favor and do not let the bellyaching you've heard discourage
you from just digging into the job and methodically removing the dash.  Please
believe me when I say, although time-consuming, it is not that difficult of a
task.  You stay relatively clean and you can sit sipping coffee and smoking
butts while you do a lot of it.  I admit it is not the twenty minute job it would
be in a Chevy Impala, but it goes fairly quickly ONCE you decide to do it.
And, it all goes back together much more quickly than it came apart.

I think by hacking apart the heater box you would be adding uncertainty and
meanness to a straightforward job.  Also, if something goes awry, you'll spend
far more time to correct a botched attempt than if you had just followed the
well used path.

As with most things, the thought of it is far worse than the experience.

George