Fix broken flapper door

2013 SUBARU OUTBACK

110,000 MILES • 2.5L • 4 CYL • 4WD • AUTOMATIC

ERICH PETERSON

MEMBER
36 POSTS

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

Oct 19, 2021 at 12:20 PM

JACOBANDNICKOLAS

✓Experienced Mechanic
110,240 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.

Images (Click to enlarge)

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Oct 19, 2021 at 1:21 PM

ERICH PETERSON

MEMBER
36 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.

Oct 20, 2021 at 5:33 AM

JACOBANDNICKOLAS

✓Experienced Mechanic
110,240 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

Oct 20, 2021 at 12:19 PM

ERICH PETERSON

MEMBER
36 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.

Oct 23, 2021 at 2:38 AM

JACOBANDNICKOLAS

✓Experienced Mechanic
110,240 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.

Images (Click to enlarge)

Professional Diagram for 2CarPros Members
Click here to log in and view diagram.

Oct 23, 2021 at 12:31 PM

Repair Safety Notice: This information is for general instructional purposes only. Vehicle repair can be dangerous. Verify all information, follow manufacturer service procedures, use proper tools and safety equipment, and consult a qualified repair shop when needed.