I have a new dash to go in and have studied the Rave a bit on the HVAC “box”, but I’m thinking the blend doors or something like that is wonky with how weak the air is coming out of the upper vents.

When I have the dashboard out to get the new one in, I’m planning on a detailed inspection, but I’ve never messed with one of these assemblies before and wondered if anyone had some ideas.

The foot vents work great and blow plenty hard for the rear as well (the ones coming off the center console). I wondered about this last summer as the AC is ice cold (including the rear unit), but again, seemed like it was blowing pretty weak from the main vents.

The air is plenty warm and the defroster works perfect, but I don’t recall the main vents being this weak in my last 2 D2s. I replaced the foam for the center vents when I put the new head unit in, but there is still a noticeable difference in air flow from driver to passenger vents.

Again, the heat and AC work great, but am not sure where to start other than inspect in detail when the dash is out.

 

Mine was full of leaves, all the way to the heater core. Recommend you pull the blower housing and clean everything out. Also, drop the glove box and drivers side fuse box cover and make sure all the linkages are connected properly. The left and right have separate linkages for the air blend door for temperature control. Diversion doors - defrost, dashboard vents, floor vents are all the same left to right. Once you have the dash off you will be able to see down in from the top, but I kinda doubt there is an issue with diverting doors.

 

OK, so it sounds like the general inspection and cleaning and such is really what I need to do.

Something that’s been a bit odd is that it feels like a breeze almost is making it in at freeway speeds. As this winter has been pretty bad, it has forced me to keep the heat on HI and the fan speed higher than I think I should need. I know Discos are not sealed up particularly well, and wind noise and the like are inherent, but I think something is amiss- and I think it is related to my initial questions.

My A Pilar trim is wasted and the cowl has a big crack right down the middle (both to be replaced in the coming weeks when I do the windshield), but I’ve wondered if the blower housing was goofed up in some way or another as well allowing the “leak”. I have zero water intrusion that I’m aware of. I can only deduce that the crack is letting more air get shoved in (there also is not a “filter” on the cowl at this time) when I’m at speed. If I let it sit and idle or am going at slower speeds, it will turn into a right toasty oven in the cab (which I don’t mind as the Disco has been on horse service duty and I’ll ONCE AGAIN complain about our barn not being finished yet).

I’m replacing the dash as it has the warp and peel back action going on, and like many repairs just want to get everything in as good a shape as possible while I have it all apart. Pulling the dash is a bit of a bear, so I don’t want to have to do it again.

I suspect once I get the dash off, I’ll find the source.