You are in for a major project. The best approach, and not a good one, is to find a donor car in the salvage yard because you're going to be making numerous trips. The entire heater box is different with different actuators. The dual zone gimmick requires the use of an unreliable, complicated computer. Every manufacturer has trouble with their versions of these systems.
I'd like to say you just need to transplant a few parts and it will work, but the truth is there are unexpected things you're going to run into. I helped a friend rebuild a 2006 Dodge dually diesel truck a few years ago that was crashed so severely the engine got pushed back a foot and crushed the firewall and heater box. My job was to take a used normal one and rebuild it to make it into a dual zone to simply match what came in the truck, and that was a very time-consuming ordeal that involved cutting plastic, forming custom runners, and transplanting actuators. We agreed we would never attempt that again. He had a couple of parts trucks that we got the heater box from, but if we ever have to do that again we're going to search for the right box to match what the vehicle came with.
I can pretty much guarantee at some point you're going to give up and cobble something to make it work "good enough". I also watched a coworker take the entire air conditioning system off a brand new van and try to put it into a different one that a customer wanted to buy. That involved cutting and transplanting part of the firewall in our dealer's body shop, upgrading the suspension just as they do at the factory to hold the additional weight, and lots of other modifications, and that was in the late '90s when those vans didn't need silly computers to do what they do today. He spent over two weeks on that project and it looked like crp when he got done. Sure, it worked, but everyone lost their shirt on the job. We all would have been better off selling the customer the original AC-equipped van and repainting it to the color he wanted.
Please consider a to help us answer more questions.
Monday, July 2nd, 2012 AT 1:03 AM