At 07:07 PM 5/5/2012, Rocket J Squirrel wrote:
>plastic keys that trap the axle. This ain't it. It's the third one,
>located sorta midway back in the box. There are two large black
>plastic tabs that we removed, but we can't figure out how to get the
>axle/flaps out. The axle is trapped between an end cap on one end
>and the operation lever at the other.

Yes, I know the one you mean.  On 80.14 they call it the main cutoff
flap.  And the swinging flaps I mentioned they call forced air flaps.

I'm pretty sure the end cap and operating lever are red herrings,
because even with them off you still have to get the flap itself
out.  So some way or another something has to split apart or open up
in way of the axle.  Someone here has to have done it recently and
remember; but I've always figured it out, and it's never looked so
difficult after as before.  I can clearly see shaft bearing points on
the housing cover, the bottom-most part on 80.14, but I presume those
are for the passenger compartment flap.  But no!  There are two on
each side, and the inner one is too  narrow, it would only clear the
flap you're having trouble with.  You have failed to remove the
housing cover, and must gnaw at it until it comes off.

Yours,
d