A/C duct work replacement

acking pin · June 7, 2015

I have a 2003 Suburban and the blower motor can lose and dropped to the kick ;panel and sat there. I thought the motor was shot (started making noise) and I was taking my daughter and her friend to a banquet. They were dress up and hair done so ran the blower I figured what the heck, motor shot have to replace it any way. Bottom line the fan milled the whole mounting flange away! I need to replace the duct work. I now have half the truck tore apart down to the duct. Looks like the bottom half of the duct might separate, looks to be held together with a few screws and what looks like rivet heads make of plastic but it might be plastic weld locations. Looks like it might be attached to the fire wall. Can this be taken apart with out opening the A/C lines? No way to attach blower motor, would like to take this one back! Any one have any experience here? Any information greatly appreciated. Thanks

gmtech4 · June 8, 2015

Have the hvac recovered ,

Remove dash braces and brackets

SO ALL THATS LEFT IS THE HVAC AIR BOX !!!

Remove it , separate the box, replace the half and reinstall,,,

It is a bitch of a job , take pics for harness routing etc etc etc , take notes

acking pin · June 10, 2015

Have the hvac recovered ,

Remove dash braces and brackets

SO ALL THATS LEFT IS THE HVAC AIR BOX !!!

Remove it , separate the box, replace the half and reinstall,,,

It is a bitch of a job , take pics for harness routing etc etc

acking pin · June 10, 2015

Was still able to order the lower half of the duct ($100) so that was good. Needed the VIN was more than one stile, duel climate ect. Dealer says $1150.00 in labor to do the job. I wish I new more about the A/C and a way to recover it. Tomorrow I might look at the duct work closely. Right now I can still use the truck even though I have the front of the dash off and the glove box as well as the center counsel. This alone is a garage full of parts. Truck is a Z71 lots off stuff, thanks for the info Don.

gmtech4 · June 10, 2015

Was still able to order the lower half of the duct ($100) so that was good. Needed the VIN was more than one stile, duel climate ect. Dealer says $1150.00 in labor to do the job. I wish I new more about the A/C and a way to recover it. Tomorrow I might look at the duct work closely. Right now I can still use the truck even though I have the front of the dash off and the glove box as well as the center counsel. This alone is a garage full of parts. Truck is a Z71 lots off stuff, thanks for the info Don.

You HAVE to recover it at a shop ,

If you try and cheat your way thru this aweful job , it WILL bite you ,

IT IS A MAJOR PITA !!!! Not a job for a DYI home wrench , at least look into Alldata . Com

acking pin · June 28, 2015

Still taking things apart, major job. What have I gotten myself in to? Have a lot of stuff out but still the metal structure is not lose. Steering Colum? Does it come out the top? Looks like maybe. $1150 would have been a steal.

gmtech4 · June 29, 2015

Still taking things apart, major job. What have I gotten myself in to? Have a lot of stuff out but still the metal structure is not lose. Steering Colum? Does it come out the top? Looks like maybe. $1150 would have been a steal.

I told you ....

Yes , steering column goes , it ALL goes !!!!!!

Get alldata

Edited June 29, 2015 by govtech4

acking pin · June 29, 2015

Found some good video (Chevrolet Tahoe A/C evaporator removal) you tube. Better information using -Plenum box and evaporator. That helped make progress. Amazed at the clueless that feel a need to make a video.

CapitalTruck · June 29, 2015

I would be more thankful than amazed! Those clueless folks helped you out!

acking pin · June 30, 2015

I said I found some good video. Not the type where someone has you watch while he heats up a screwdriver to melt through a quick disconnect because they don't know how to take them apart.

acking pin · July 12, 2015

I’m done. Helpful tips, remove console as a whole unit by removing the seats and 2 10mm bolts and 4 screws up front. Get an illustration of the duct work it will show the location of the 5 or 6 bolts through the firewall. Watch the video I mentioned in the earlier post he is the man. But they don’t show everything. Dash stays in truck pull passenger side back and upword tie for support to roof rack. Plenty of room to work. Just a few tips I wish I had known. Be patient.

txab · July 12, 2015

I’m done. Helpful tips, remove console as a whole unit by removing the seats and 2 10mm bolts and 4 screws up front. Get an illustration of the duct work it will show the location of the 5 or 6 bolts through the firewall. Watch the video I mentioned in the earlier post he is the man. But they don’t show everything. Dash stays in truck pull passenger side back and upword tie for support to roof rack. Plenty of room to work. Just a few tips I wish I had known. Be patient.

Why not post a link to the video, you could be helping the next guy

CapitalTruck · July 15, 2015

I’m done. Helpful tips, remove console as a whole unit by removing the seats and 2 10mm bolts and 4 screws up front. Get an illustration of the duct work it will show the location of the 5 or 6 bolts through the firewall. Watch the video I mentioned in the earlier post he is the man. But they don’t show everything. Dash stays in truck pull passenger side back and upword tie for support to roof rack. Plenty of room to work. Just a few tips I wish I had known. Be patient.

Congratulations! It feels so good to get a big project out of the way. Now...post that link!

GMLS2 · June 10, 2021

On 7/14/2015 at 11:14 PM, CapitalTruck said:

Congratulations! It feels so good to get a big project out of the way. Now...post that link!

Wish he had shared link. Im in same mess. Garage full of parts and still not necessary the duct. Something died in mine. Smells so bad cant even be near it for more then a minute. May just get rid of it pay loan off. Im so pissed that they make it rhus impossible to get a dead rodent out of air ducts.

drokmofo · June 28, 2021

I have to do this to my 2000 k1500. fkn pack rat made its home in the ductwork while I was waiting to replace fuel pump. removed all the crap that I could reach. can still feel a bit more up under defrost vents. gonna tackle this myself, any advice is appreciated.