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what should I use for the seal between the AC Evaporator box and the firewall.
Got the old box off last night and it looks like kind of a rubbery material is what they originally used. Should I just use a tube if some generic rubber weatherstripping stuff?
You may want to check out your local home improvement store like Lowes, Home Depot, ect., and look at a product called 'rope caulk', comes on a small spool, and can pull one or more widths of the rope caulk off at a time, and cut to your desired length. This stuff is very close to consistency of the stuff factory used for many sealing applications like heater boxes, heater blower motor, ect. Stays soft and tacky, and is easy to work with, and you can double up on larger areas/holes to be filled/sealed, and not nearly as messy as RTV.
The closest thing I found is windshield sealing rope. You can get it at your local parts store for around $5. It's black and sticky as hell. Just outline the box with it where the seals go and press the box in place. The rope is about 3/8 inch round and comes in about 25 foot lengths. I've also used it for other sealing jobs in place of silicon.
In automotive jargon, the stuff is called "strip-calk"... available at NAPA & others. 3M makes it, as well as several other manufacturers.
I am currently over-hauling the A/C system for someone (Jenny) and I am using strip calk to re-seal the evap box. Factory used a special gasket that is available from Dr ReBuild (& others), but strip calk is commonly used in lieu of the original GM seal. In fact, the box I am currently working on had been serviced & re-sealed using strip calk. Probably going to replace the orifice valve with one of those VOV items to improve low speed (idle) cooling) as well.
The home Depot stuff (rope calk) may work fine as well. Never used it myself.
I also had to deal with a separated & torn gasket that seals the evap core to the passenger side half of the box. Used contact cement to re-attach the gasket, and, to repair a tear. Worked great. Cleaned off the surfaces with lacquer thinner first.