Fix broken flapper door

Tiny
ERICH PETERSON
  • MEMBER
  • 2013 SUBARU OUTBACK
  • 2.5L
  • 4 CYL
  • 4WD
  • AUTOMATIC
  • 110,000 MILES
While installing a new mode selector actuator, one of the plastic arms for one of the flapper doors broke flush. Local repair shop wants $2,000.00 to fix, because entire heater core box has to be replaced $900.00 from Subaru (Subaru doesn't sell a repair kit or just the door). Was quoted 11 hours of labor, because the dash has to be pulled off. I would like to attempt this repair myself.

My question is, if I can find just the flapper door, is it possible to replace just the door without removing the entire heater core box (once removing the dash)?

Thanks
Tuesday, October 19th, 2021 AT 7:20 PM

5 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,867 POSTS
Hi,

Chances are you won't be able to replace it without the removal of the components. The HVAC box needs taken apart.

I attached the directions for the removal of the instrument panel assembly. Note: You will need to drain the engine coolant and recover the freon from the A/C system for this procedure. After that, I included the directions for the heater core case removal.

I hope this helps. Let me know if you have other questions.

Take care,

Joe

See pics below.
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Tuesday, October 19th, 2021 AT 8:21 PM
Tiny
ERICH PETERSON
  • MEMBER
  • 28 POSTS
Thanks for all the info. Once I pull the dash and get a better look at things, I'm hoping I can either drill and tap a screw or epoxy the arm back to the flapper. Will update when I get a better look at things.
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Wednesday, October 20th, 2021 AT 12:33 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,867 POSTS
Hi,

You are very welcome. Let me know if there is anything I can do to help. Hopefully, you won't have to remove everything.

Take care,

Joe
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Wednesday, October 20th, 2021 AT 7:19 PM
Tiny
ERICH PETERSON
  • MEMBER
  • 28 POSTS
Update: So, there was still some of the flapper arm sticking out of the hole, so I tried gluing the rest of the arm to it using Loctite brand plastic adhesive. It appears to have glued, and I will be trying to reinstall the mode actuator soon.

Does anyone have a picture of which groove (cam) on the actuator do each of the three flapper arms go into? I don't want it to break it again! As I think I put it in wrong the first time, and that is why it broke.
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Saturday, October 23rd, 2021 AT 9:38 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,867 POSTS
Hi,

Let's hope it holds. As far as the linkage, I found two pics that may or may not help. Pic 2 is likely easier to follow.

Let me know if this helps.

Joe

See pics below.
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Saturday, October 23rd, 2021 AT 7:31 PM

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