Shut the front door, there's a hole in the case?

 

Um yeah..... that bigass hole in the blower housing is a big problem. To properly repair that will require replacing the entire lower half of the air unit casing. Wow - never seen that happen before. Thats gonna be painful to replace as it will require totally removing the floor console as well as most of the dash. Only cheap solution I can think of would be to mold some sort of plastic or thin aluminum (like .020) to fit over the hole as good as possible then seal that in place to close it back up. If you go that route remove the blower first as that will give you better access to the inside as well to make sure no caulking or anything will interfere with the blower.

The lower half of the casing is not a separate available part new but may be able to get one used. As new the entire casing (upper and lower half) are sold as one part. That casing contains all of the blend doors, sensors, AC coil, heater core, and blower. Then you still need the lower hush panel which I gave a part number for earlier in the thread.

https://nemigaparts.com/cat_spares/e...n/09/tn09-012/

The problem with that hole is that whenever the defrost mode opens the recirc door some to reduce condensation, cold outside air goes into the casing and then goes right back out that huge hole. Normally the air is then forced through the heater core and ac coil and blend doors to the desired temp. Fixing that will also dramatically increase the airflow through all the vents.

There's yer problem.... lol

 

Wow. Thank you guys so much just bought this hummer a year ago and running into so many problems.

 

An immediate fix would be to get some Gorilla brand (it is vastly stronger and stickier than cheap duct tape) duct tape and seal it off. That will at least provide some relief.

 

Foil Tape

 

Yup, part of the blower housing is missing. Looks like the H2 may have been crashed after all, like I suspected in my prior post?
That would take some force to destroy the housing like that. And would explain the missing cover.

2 hack solutions, which cost practically nothing:
1. Foil tape, as already mentioned. Actually you should use thick insulated foil tape instead, and you should see both in hardware stores like Home Depot or Lowe's in the HVAC isle. Both are super easy and fast to use, and are designed to be a permanent fix for hot or cold environments. So no further work required for the life of your H2.

2. take a small sheet of black ABS plastic from a place like Home Depot, Michaels or a plastic shop. Cut to shape. Heat up with a heat gun or soldering iron and melt it into place on the housing. This is a little trick I learned from one of the people on this board for reattaching broken trim panel clip plastic posts. Takes some patience and precision to do.

The proper way to fix this mess would be to replace the housing, but that will cost you bueno $$ and time.