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I'm stuck - '97 960 Heater Core rear ducts removal

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

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wasaabi
Posts: 24
Joined: Tue Aug 13, 2013 5:31 pm
Year and Model: β€˜08 XC70, β€˜97 965
Location: Pa
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wasaabi

I'm stuck - '97 960 Heater Core rear ducts removal

Post by wasaabi » Thu Sep 19, 2019 3:44 pm

I'm finally tackling this job for the first time, trying to be patient. The car is in excellent condition and I would like to keep it on the road for many years.

I am stuck at removing the lower air distribution box. There are two ducts that come out of it that go to the rear. I have removed the one screw on the tab that holds it in (VIDA doc claims two screws but I only found one).

The structure of the lower air distribution box appears to be able to be split in half horizontally, so I thought maybe I could do it that way, but the rear of it is inaccessible and so I cannot reach those tabs to fully split it.

Both seats are in and all the way towards the rear. I would be afraid to reconnect the battery with everything disconnected just to move the seats forward to remove them and peel the carpet back far enough to release the rear ducts. There has to be a better way.

The overlap of the rear ducts over the distribution box lips is about 1 inch each. Those rear ducts just won't budge. Has anyone tried cutting the left side of each rear duct, or even the entire duct, and then taping it back together with aluminum duct tape? Any other ideas?


2008 XC70 167K
1997 965 146K "The 97"
1990 745 GLE 16-Valve manual + electric overdrive (sold 125K)

wasaabi
Posts: 24
Joined: Tue Aug 13, 2013 5:31 pm
Year and Model: β€˜08 XC70, β€˜97 965
Location: Pa
Has thanked: 2 times
Been thanked: 0
United States of America
wasaabi

Re: I'm stuck - '97 960 Heater Core rear ducts removal

Post by wasaabi » Thu Sep 19, 2019 4:47 pm

Since it was simple to do and easily fixable, I did cut the ducts as shown by the pics below. But while the box moves a bit, it will not come out, yet I cannot figure out what is holding it in. Here are pics of the box with the opening "doors" cut into the ducts:

Image

Image

Image

Help is appreciated on how to get this lower air distributor out. Thanks!


2008 XC70 167K
1997 965 146K "The 97"
1990 745 GLE 16-Valve manual + electric overdrive (sold 125K)

wasaabi
Posts: 24
Joined: Tue Aug 13, 2013 5:31 pm
Year and Model: β€˜08 XC70, β€˜97 965
Location: Pa
Has thanked: 2 times
Been thanked: 0
United States of America
wasaabi

Re: I'm stuck - '97 960 Heater Core rear ducts removal

Post by wasaabi » Thu Sep 19, 2019 5:54 pm

Update: I realized that I misunderstood the instructions and tried to pull out the air distributor to the side, but the center tunnel hump would not let it squeeze through. So I cut each rear duct a few inches back, which I will repair upon reinstallation. I was then able to pull the distributor towards the *rear* of the car. Then it just slips right out. Felt a bit stupid but it;s out so now onto the next step tomorrow...


2008 XC70 167K
1997 965 146K "The 97"
1990 745 GLE 16-Valve manual + electric overdrive (sold 125K)

dm635
Posts: 102
Joined: Wed Jan 16, 2008 9:46 pm
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Location: Lou. Ky.
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dm635

Re: I'm stuck - '97 960 Heater Core rear ducts removal

Post by dm635 » Fri Sep 20, 2019 7:08 am

I feel for you doing this job. I did it to my 960 this past winter. Not a fun job. And I did use some of the aluminum duct tape to seal some of the areas. Some parts of it do not go back in as easily as it came out. I practiced first by going to a junkyard and tearing a junker apart. Don't want to think about ever doing it again. The all metal core I put in better last. I don't know if I'd do it again. At least not do it in the cold of winter.
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wasaabi


96-964
91'745

86-635CSi 215K



Previous- 83 245T, 84 242, 85 242T, 92 960, 94 960, 95-964, 95-945

wasaabi
Posts: 24
Joined: Tue Aug 13, 2013 5:31 pm
Year and Model: β€˜08 XC70, β€˜97 965
Location: Pa
Has thanked: 2 times
Been thanked: 0
United States of America
wasaabi

Re: I'm stuck - '97 960 Heater Core rear ducts removal

Post by wasaabi » Fri Sep 20, 2019 10:35 am

Thanks for the support. It gives me a boost to hear from people who have been there before! I did the bypass last winter after I couldn't see through the foggy windshield anymore. The core I got is the Hella/Behr (eBay from Eastern Europe) but it does have plastic connectors. I want to get a decade out of it (at least), hopefully not being too naive on that.

We're on a good streak of weather in PA so I'm about to hit the job again for a few hours and see if I can actually access the core today. I'm taking a million photos which I will put into a doc and upload for others.


2008 XC70 167K
1997 965 146K "The 97"
1990 745 GLE 16-Valve manual + electric overdrive (sold 125K)

dm635
Posts: 102
Joined: Wed Jan 16, 2008 9:46 pm
Year and Model:
Location: Lou. Ky.
Has thanked: 0
Been thanked: 6 times
dm635

Re: I'm stuck - '97 960 Heater Core rear ducts removal

Post by dm635 » Fri Sep 20, 2019 11:37 am

At 1st I did order the aluminum core with plastic end tanks. I opened the outside box and the plastic connectors were sticking out of the box from damage. I wasn't about to take a chance of using it as a replacement.

The outside box had no damage at all. They picked the box with the core in in it and the plastic ends sticking out of the box off the shelf and sent it to me. I could not believe it when I saw it. Was highly upset they sent me a damaged part and I was not going to install it with potential damage. So that delayed my reinstall due to having to get a refund and ordering from another vender. That took an extra week and I needed my car up and running. As upset as I am with this well known vender sending me crap I did order control arm bushings from them this morning. Only for the free shipping over $49. My son refuses to order from them due to several attempts to get the correct Bilstein's. Kept getting their junk. The company has made some good changes, I'll give them that.


96-964
91'745

86-635CSi 215K



Previous- 83 245T, 84 242, 85 242T, 92 960, 94 960, 95-964, 95-945

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