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Unread 10-21-2014, 08:22 AM   #1
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
Need HVAC vacuum line help

The vacuum line going into the firewall that controls the vent positioning broke up near the firewall in my 97. What's left of it snaps like twigs when handled. I have ordered the entire vacuum line assembly to replace it all.

My question is this: unless I missed the section in the FSM, I cannot see where and how to replace the firewall port (the wee tube that splits off and goes right in by the AC tubes...). Can this be done without removing the entire dashboard?

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Unread 10-21-2014, 10:29 AM   #2
JWebber
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1999 TJ Wrangler 
 
Join Date: Aug 2011
Location: Lewisville, Texas
Posts: 973
You might have to pull the dash back on that side to get up in there to replace the whole line up to the control panel. When I did my heater core and had to pull the dash out to get to all, I noticed the small vac line running thru to panel. Unless you can get your hands up in there with dash in place might be hard to do.
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Unread 10-21-2014, 11:57 AM   #3
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
Thanks. I was afraid of that. That's partially why I didn't replace that aging line years ago. I fixed it out in the bush this weekend with some small engine gas tubing over what pieces were left and didn't snap instantly, but it's only a matter of time before the remaining plastic line fractures.
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Unread 10-21-2014, 03:50 PM   #4
JWebber
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1999 TJ Wrangler 
 
Join Date: Aug 2011
Location: Lewisville, Texas
Posts: 973
I see, so the rest of the line going into the fire wall is brittle as well, past the tee fitting correct?
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Unread 10-21-2014, 04:36 PM   #5
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
Yes, correct. I'm pretty sure its safe to assume the entire line is nearing the end of its useful life.

Surely someone else up here has put eyes on that fitting as it goes into the firewall and comes out inside somewhere........
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Unread 10-22-2014, 08:53 AM   #6
trickydick
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2005 TJ Wrangler 
 
Join Date: Jan 2012
Location: geronimo, ok
Posts: 189


If you see the vacuum connector to the right of the fuse block, the vacuum line for your hvac controls runs through the fire wall inside a big rubber plug thingy with two hard line for the heat or A/C, do yourself a massive favor here and just drill a hole a couple of inches above the "big rubber plug thingy" and jump a new line to the back of that vacuum connector.
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Unread 10-22-2014, 09:56 AM   #7
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
Thanks. The 97 looks a good bit different, but your suggestion of drilling a new hole is interesting. I'm just going to have to get up in there and have a good look this weekend. What I can't see in initial poking around is where the bundle of colored vacuum lines terminate, it disappears behind a bracket or something, I presume into a transition connector that splits between the duct controls and the blend door controls

It just stuns me nobody up here with a 97-99 yr model has had to deal with this.....
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Unread 10-22-2014, 02:44 PM   #8
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
I finally found the part (I think). Arrives tomorrow. Seems there are two separate pieces. The engine bay part, and the inside part. 4864997AB inside and 55037393AE outside. As soon as the inside part arrives, I should get some idea of how it passes through the firewall, and if there is anything but a grommet between. If it's just a grommet, I should be able to lube it up and pass it through from inside, I hope....
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Unread 10-26-2014, 04:03 PM   #9
JeffBowser
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1997 TJ Wrangler 
 
Join Date: Oct 2010
Location: SE Florida, Florida
Posts: 1,529
Ok, I replaced the outside, there were several places that were "crispy". The part I really needed though, was a part of the inside kit. Here's where it got tricky - to replace the entire inside kit, you need to remove the dash. So, I took the piece that broke off off the inside kit and just used that. It goes through the firewall, just pushes straight through. Inside, you have to remove the fuse block, and then you can access where the vacuum source line hooks into it's other half via a simple sleeve. I'll save the rest of the kit for when I have my heater core replaced.
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