Fix broken flapper door

Tiny
ERICH PETERSON
  • MEMBER
  • 2013 SUBARU OUTBACK
  • 2.5L
  • 4 CYL
  • 4WD
  • AUTOMATIC
  • 110,000 MILES
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
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Tuesday, October 19th, 2021 AT 7:20 PM

5 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
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.
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Tuesday, October 19th, 2021 AT 8:21 PM
Tiny
ERICH PETERSON
  • MEMBER
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.
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Wednesday, October 20th, 2021 AT 12:33 PM
Tiny
JACOBANDNICKOLAS
  • EXPERT
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
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Wednesday, October 20th, 2021 AT 7:19 PM
Tiny
ERICH PETERSON
  • MEMBER
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.
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Saturday, October 23rd, 2021 AT 9:38 AM
Tiny
JACOBANDNICKOLAS
  • EXPERT
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.
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Saturday, October 23rd, 2021 AT 7:31 PM

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