How to replace A/C Evaporator Duct Hose
 

I replaced the hoses on my 87 cabrio, along with the dryer and expansion valve. Cleaned the evaporator etc. ACKits was very helpful in creating new hoses. The job was time consuming but not very diffecult.

My current issue is that the flexible duct from the AC blower disintegrated and I was wondering how to get a replacement. I am currently using some aluminum duct tape to make a hose.

Replcement of the hose will be diffecult. There is not much room to work in the smugglers box. Any tips on this?

Searched quite a bit but found no hints.

I assume you mean the 80 mm size duct which is either on BO or NLA from Porsche (I can't remember which). If so, the 3.25" size (single wall rubberized fabric supported by copper plated steel wires) available from Aircraft Spruce is a close enough fit. I recently ordered a 2 or 3 ft length (order minimum length) of it for an AC refurbishment project and I only need about six to eight inches. How much do you need? Send me a private message. If you need other sizes check out Aircraft Spruce's web site.

Mighty Flow #96093.

It's marketed as the ducting that leads to an engine air filter housing. It’s the perfect diameter. At $8.00 for about three feet, it's priced right (you'll only need about 6" of hose). Check your local corner parts house.

I think you'll find installing the hose is no big deal. Temporarily remove the two straps locking the evap. box in place to gain a bit of wiggle room.

Image of PN 05-29813 Aircraft Spruce Aeroduct tube CAT-13 3-1/4" ID. Image shows trial fit through firewall hole.http://forums.pelicanparts.com/uploa...1149051275.jpg

Home Depot find to replace deteriorated evap to vent hose:

$3.50 Neoprene Rubber PVC coupler with stainless compression clamp......discard the stiff compression clamp and reuse the orig hose clamps. There is about 1/4" overlap on each end sufficient to secure to the box and vent outlets. I don't recall the size (took my evap box cover with me) but I'll post the size and SKU later for future reference.

WOW, my old hose must have been leaking....huge improvement in vent air flow. "While you're in there" cut a piece of 1/2" pipe insulation foam in half lengthwise and stuff one on each of the short sides of the box to block air from comming up the sides - works well and the cover will keep in in place. (Use the cheapo light grey stuff not the expensive dense rubber type)

Part is a 3 No Hub Coupling U95-003 Jones Stephens Co. $3.94

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Installed. Apparently, silicon turbo hose is another option. (ebay search turbo hose)



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