Just about had frost bite on my feet this morning, (1½ hour drive at 12°). Warmed the car up this morning for about 15 minutes as usual when its this cold, frost. For a little while I've been hearing the door/diffusor in the heater box popping when the actuator kicks in. This morning when I left, one of the doors/diffusors was stuck in the partial defrost/vent position. No floor heat. I tried playing with the buttons, but nothing other than hearing the actuator a little. When I got to work I shut the car off and the heard the actuators. Started it back up, and it worked like it was supposed to, floor heat. Will it work tonight I can't answer that. While I was pushing the buttons again, vent, out came a bunch of the old dry rotted foam/sponge seal. I'm assuming that this is/was binding the door/diffusor.
Questions are: - Is the foam seal available, or is it a trip to Home Depot and make something work? - How much is involved tearing into this? And how much of the dash should I pull apart to get to it? - I suppose that this would be a great time to replace the heater core.