BTDT. You MUST find the little plastic "bolt" that holds the linkage together for the floor vents and remove it BEFORE you take the box apart -- otherwise, the flex link will almost certainly break. Rather pricy to replace -- I drilled and wired mine.

The box is held together by screws (side boxes for the floor vents and top cover) and clips. Watch the clips, they tend to fly around and won't survive being stepped on.

you must get the screen on the evaporator back on the new one in EXACTLY the same place as on the old one or the box won't go together, it fits very tightly. I had to cut off the goop used on the old one.

Going back together, make absolutely certain the box sections fit together properly before installing the clips -- there is a lip and slot arrangement, and the box will leak if you don't get it together right. I had to scrape off all the silicone sealant helpfully applied by the previous idiot.....

Check all the servos for correct operation. Most of them will be leaking, so plan on the extra $200 or so to replace them all while you have it on the floor, beats the h... out of doing this again to get the recirc door or floor vents to work next winter!

I can't believe it only took you 4 hours -- took me all day!. Next time woudl be faster, of course.

Peter

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1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!