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Well I spend the good part of 9 hours today changing my heater core. Actually it is 2 1/2 times I've done this, the first time got over half way into decided I'd wait until I had all new hoses so I put everything back together. Then I replaced it a few weeks later which was about a year ago. A few months ago it sprung a leak, again!
So I hunkered down on this rainy father's day, and tore apart the vette. Well the good thing I can do it in just under 9 hrs now, first time was much longer. I also found a couple things that you don't have to remove and a few more tricks along the way.
Verdict, a success. Thankfully no more coolant scent with the AC.
I wonder if the originial units can be reconditioned? I think the problem with the replacement parts is aluminum that is just too thin.
A very good friend of mine is an A-line tech for a Dodge dealer in Delaware. They were having serious problems with the Caravan AC evaps. The problem? Leaves would get into the heater box, and the acid was eating he aluminum... causing mucho problems. Junk.
It is a real shame you are having to do this multiple times. I hope it's works this time!!!