Larry:

Having just finished the job myself (plus evaporator), here's some tips!

You do not have to pull the AC box to replace the servos, but it will be a PITA (less than pumping down a leak-free AC system, though!).

You will need an 8mm nut driver and 8mm ratchet, and a 10mm wrench, plus a 24mm to remove the headlight switch nut. Small and large phillips.

You must, alas, remove the console to replace the floor flap servo, but if you don't need that one, you can leave it in.

You need a flexible blade putty knife to get the trim strips off the speaker covers, preferably blunt so you don's scratch anything or cut yourself like I did.

Removing the trim on the A pillar is a huge pain, my clips didn't come (they are still in there) and the guys who replaced the windshield a couple years ago glued them to the glass, so I suspect the are ruined anyway. You have to persuade the clip of out of the A pillar from behind -- DO NOT USE A SCREWDRIVER unless you want to replace the windshield if you slip.....

All but one of the servos is held on by little twist lock feet and a locking tab. The center vent on on top has three posts and pushon clips -- get new clips, I shot two of them across the room since I had to break the pins off to get the sero off.

Otherwise, fairly easy, if very fiddlesome.

If the servo inside the box (diverter flap) is bad, you must remove the AC box on pre 1990 models. later models let you reach through the top.

For just servo replacement, you don't have to remove the cross member under the dash.

Going back in, I found it much easier to remove the center vent than to get the hoses connected with it in place -- one screw on the right side, two spring clips on the left. A small Torx screwdriver fits nicely into the hole on the spring clip so you can pull it inward to release the clip.

More notes available if you need them.

Peter

__________________
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!