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When you turn the knob, do you have tension on it, like it feels like it is pulling a cable (which it should be)?
When I turn the Heat-Cool dial I can feel it turning the Mixing vane with my other hand.
Does your temp gauge show what seems to be an appropriate temperature? If you feel the hoses going to the firewall (to the heater core) are they hot (both of them)? How many miles are on the car, and have you had the timing belt replaced? How about the water pump?
That's right- does your blue light go off in a decent amount of time, just a few minutes? You don't have a check engine light on at all do you?
No Check Engine light on
Blue light goes off in reasonable time (few minutes)
Both hoses seem warm to touch
The Heat/Cool Dial doesnt have a lot of resistance but I do feel the mixing vane moving, not sure if there is another internal vane.
Odd part was in the summer, sometimes if you touched the heat/cool dial it would only push Hot air even if the AC was on. However when I pushed the connection to the lower mixing vane back in place it seemed to stop that.
Can you feel the connection under the airbox (under the dash) where the cable connects to the flap? If so, see if you can activate it by hand, make sure the lever is actually moving the flap. You should audibly hear it move from one side to the other, at least at the end stops of hot and cold it should kind of "thump" into place, especially if you have the fan on high to increase air pressure on the flap.
So I feel where the Snap Bushing is connected to the blend box, it was real loose. In fact I jiggle it a bit while I had fan on high, and it just fell out. then I heard the door Thump into place. The air now is just warm, not hot. However with the snap bushing out, it cont go on full code or full hot. Wondering if this means I have to take of the dash to fix the blend door now.
Do you have a picture of the piece that fell out? You mean the piece that is basically where the door pivots?
this is it when it is pushed in place, I can hold it in with my hand although it doesnt see to change Hot to Cold just seems to stay warm
I have "fixed" one of those by jamming a block underneath it to keep to from falling out- but yes, the only way to really "fix" it is to pull the dash and replace that part of the airbox.