Glad you got it together. When I had that airbox, and had the same problem, I used a safety wire spinner tool to wrap the clip area -- I was able to do this from the top.

Now I have a monster GM fan box in there that really moves some air.

Chuck.H
'89 TurboLookTarga, 423k miles

Install Clips in the Smugglers Box
 

The clips can be installed while in the box if you're willing to modify a large screwdriver (MAPP gas)
The process:
--- using a circlip expander, spread the clip wide leaving it stretched another 1mm or so. It will still fit plenty snug.
--- take your LARGE screwdriver (that fits into clip), apply MAPP gas, bend to 45* angle
--- tie string onto clip using the hole provided
--- push screwdriver into the side of the clip about 2/3 of the way. This will spread the nose of the clip another mm or two and fill fit on the lips of the evap box.
--- push onto the lips of the evap box, hold the clip in place (tool of your choice), slide the screwdriver off and slide the clip into place.
--- remove string
Works easier than it sounds....
http://forums.pelicanparts.com/uploa...1539396874.jpg
http://forums.pelicanparts.com/uploa...1539396874.jpg
http://forums.pelicanparts.com/uploa...1539396874.jpg
http://forums.pelicanparts.com/uploa...1539396874.jpg

Alternative to clips... forget the clips. With blower top seated on bottom half of plenum, place foam between top of blower housing and smugglers hatch. Need to be correct about foam's thickness so not too much pressure is exerted on plenum---it can/will break. When blower top's seated and with right just enough pressure on it, it's not going anywhere.

I used some "electric fence" wire. Don't know the size, maybe 18 gauge or so and it's solid. I positioned the wire through one hole, twisted it a couple of times so it wouldn't pull through. Then, hooked the bottom edge of the clip into the bottom box. Once hooked, simple pull straight up and "CLICK". It was pretty easy.

Thank you for this tip.

Oh...and no lube was required.

+1 - I did this. Easy on/off next time.

I am quite routined now in getting the top of the box off in about 10-15 minutes while it remains connected. Getting the clips off the first time might take longer.

To put the clips back on, I stretched them a bit with the circlip pliers, just so I can put a large screwdriver in (outside the car) and stretched one side a fair bit wider. I put a small tiewrap through on hole and on the tiewrap I twist and electrical copper wire. The wire acts as a safeguard if I drop the clip. I can just pull it up by pulling the wire out - clip attached.

Before trying to slide the clip on with the wider side first, I use a small blast of silicone spray and the just pust the clip on with a large flathead screwdriver to push it along. As said, wide side first, it slides on easy for the first millimeters and the it needs a fair amount of power.
The hardest on is the one on the side facing the steering column on my car and sometimes I just skip it and use a small tiewrap around the clip holders if pressed for time.

I removed and reinstalled the clips a while back with the evaporator box in the car when I replaced the evaporator fan motor with the upgraded one from Griffiths. It was a bit of a challenge - I also attached some dental floss to the clips in case I dropped some into the well. If I remember correctly, I was able to expand some of them and slide them on from the side, some I had hold the top part with needle nose pliers through the hole and then snap on after forcing the bottom part to expand with a screw driver. As I stated it was an adventure but certainly doable.
Dave

Hahaha, search is my friend today. I kind of remember in previous searches that the topic of these clips came up. I was fussing with them earlier this morning with none of these well advised safe guards. I’m glad I took a moment to pause, reflect and search. I’ll let you know how it goes. I do have a lovely danish oil rubbed German Black Forest footrest that I’ll be damned if I pull that out again. It’s the principle.http://forums.pelicanparts.com/uploa...1585228655.jpg

http://forums.pelicanparts.com/uploa...1585228687.jpg

Bent screwdriver suggestion worked great for me the last time that I tackled this project. Tied some 30# test Fireline thru the hole, just in case I popped one or needed upward pull, and guided them right into place. Removed the line and was back in business

Upside is that I now have a screwdriver that works around corners.

I like that idea as well!

For any of you that need one of these clips the part number is 901-573-904-00.

Porsche calls it a tensioner spring. I bought mine from 5150 Motorsports for $1.98 each.

I was able to get one factory clip in with the bent screwdriver method. I used the drill and small screw method for another tab. The box top is secure, but after a couple hours futzing around with this minor job, I yield to the tight quarters of the 911 frunk. Car wins.

Minor issue considering what’s going on in the world around us. Take care all.

A good night’s sleep and a fresh approach provided a couple of small victories. I was able to secure the 2nd clip that I found in the bottom of evaporator no man’s land. I used the wire pulling method for that one with dental floss for recovery insurance. I also added a third bracket that I cobbled together from my misc. hardware tin. Last thing to do before I close the lid is to wrap the new valve with Prestite cork/tar tape.

http://forums.pelicanparts.com/uploa...1585333473.jpg

http://forums.pelicanparts.com/uploa...1585333525.jpg

http://forums.pelicanparts.com/uploa...1585333552.jpg

Assuming you are removing the box in the smugglers well, as opposed to taking the top off the box with the complete unit out of the well.

1) Stuff rags all around the box under the lid. This way when you are trying to remove a clip it does not fall down to the bottom.

2) Thread a piece of thin wire through the hole in the clip. This way if you drop it does not fall down to the bottom.

3) While holding the wire take a flat blade screwdriver and carefully push/slide the clip off of the tabs. Do not use too much downward force as the plastic tabs of the box are fragile.

4) After the clip slides off the tab pull on the wire to retrieve the clip.

5) The plastic tabs on the box are tapered. If the box is closed all the way, the top is properly seated to the box bottom, you should be able to slide the clips back on.

6) To put the clips back, have a wire attached to the clip. Use the needle-nose pliers to grasp an ear of the clip and carefully slide the clip over the two plastic tabs and use a screwdriver to complete the push.


http://forums.pelicanparts.com/uploa...1585426925.jpg


http://forums.pelicanparts.com/uploa...1585427035.jpg

http://forums.pelicanparts.com/uploa...1585427067.jpg


http://forums.pelicanparts.com/uploa...1585427150.jpg


An alternative that can be used to secure the box top and bottom together is to screw the two together
using #4 self-tapping plastic screws (drill a pilot hole through both tabs).
This makes it easier to take the top off the box next time.