Heater Box - With A/C - Repro ~ 1967 - 1968 Mercury Cougar / 1967 - 1968 Ford Mustang

68 Base 302 F. My old 68 heater box was shot. Cracks, rusty doors, broken drain, and someone used chair foam for seals in the past. The new box was expensive, but seems much sturdier. I watched the WCC video and was able to remove the old box without much trouble. A few notes:
1. The new door rods do not have stops to keep the vacuum actuator arms from sliding too close to the box. I’m not sure how this will affect their operation as my engine is out for a rebuild.
2. Order the foam seal kit you will need most of the seals if your system is original.
3. The box I received came with the AC grommet for the evaporator tubes.
4. Installation was much more difficult than removal. Getting the blower to seat in the box while trying to get all 3 firewall studs aligned took a lot of patience, prying and swearing. I used a couple 1x1 1/2 pieces of wood. One to hold the box up and the other to pry the blower up. The drain hose was also a pain to get connected as there is limited space between the drain and floor.

Box is not an exact duplicate but did fit and looks like it will last another 53 years. It is expensive but trying to restore my old one was not worth the time and effort.

One take West Coast’s recommendation of the foam and seal kit the form that comes with the unit is too thick and hard . I did not remove the whole dash panel as Don rushes video I dropped it lowered the box below my glove box . In my 69 Xr7 . 2). New box is missing the notches in photo so you’re subject to purchasing the the grommets to metal grommets that holds the actuator handles in place. Other than that it does what it supposed to do .

 

worked fine

it was missing one of the studs going through the fire wall. I had to transplant the missing stud from the old box.

In the end, the box went in and did what it is supposed to do.It will work fine. I had two fitment problems installing it. One of the metal flaps was not in the same location as the original and I needed to modify the fitting on the small vacuum actuator in the car. Also, the foam gasket that came with the kit to mount the box to the heater blower motor was too thick and heavy. I could not make the box fit with that gasket in there. I cut the gasket in half and it was still too thick. I ended up using a soft foam gasket from another seal kit that I had and throwing away the one that came with it.