I want to thank all of you guys for the wonderful info on this site. I was able to read and printout everything I needed to remove this myself. Being a lefty was a challange since I had to use my right hand to stick up there and take the bolts out of the actuator but I finally got it!
Now to my problem. I (mr dumb a) managed to break off 4 of the 6 nipples on the programmer when I pulled/pryed off the vac hoses. The programmer ?? (I think you all call it a programmer) has the rubber nipples. I ordered the actuator (broken gear inside) and last night sat down with a bottle of super glue and tried my best to glue these 4 nipples back on. In fact one of them was the "blank" and goes nowhere. I just don't know if this is going to work. I can stick a needle down them and all the way through but not as freely as the ones I didn't break off of course. Any suggestions? Anyone have a part they would like to sell with the hoses/nipples not broke off? I assume I can't buy this part separatly and will have to buy the whole programmer if this does not work. Is that correct? From the research I have done yesterday that'* the conclusion I came too. Sorry for the long post. My first post too. Nothing like making a good impression right off the bat! BTW...this is our 5th Bonnie..we love them

bypass the nipples using regular vaccum line.
Heres my post on my programmer, see the pic just past 1/2 way down.
http://www.bonnevilleclub.com/forum/...ght=programmer

I will grab some 1/8 vacuum line tomorrow when the actuator comes in. Thanks so much for you help! The programmer is like $400 or something. I was sweating over tearing that thing up.
I'll post and let you all know if all of this work pays off.
Again...THANKS!

its the nipples that gum up and clog, so you just saved yourself a future repair anyways.

You know, I had the exact same problem on the '98 LeSabre. I ripped off ALL the nipples with some needlenose pliers, opened the holes a bit with a pin, put some very small washers behind the 7mm (as I recall) nut, then cranked that nut on really tight...it'* worked fine for like 6 months now.

Hey papatim did you just slip the 1/8 hose over the existing hoes or did you have to get some barbed connectors?
Rob

Well I went to ORiley'* at noon and got some vac hose. They didn't have 1/8 but I got one size under and had the piece with me so I made sure it would fit on there. It is snug but will go over it. Also picked up some 18gauge wire to splice in the 1 foot of extra wire from the programmer to the actuator. Man I hope this fixes everything. I have other small issues with Bonnie that I'll post if I can find an answer too but want to get the heat working first. Getting pretty cold here.

I slipped a peice of shrink tubing over the factory lines, shrunk it, then slipped rubber the vacuum line over those ,and then used a wire tie to cynch it up.

Well I got it back together and it all seems to work great. Thanks sooo much for everyones help and all of the good info. I did use the em I think 7/32 tubing and it was tight enough for them to just wiggle and slip over the hoses. I think everything will be ok underthere. I do have that little round air tubing aobut 1" around that runs up in the dash kind of in the way. It was moving with the air acuator as it moved but I took a long screwdriver and messed around with it so that I think it is out of the way now. The temp flashed the first time I started the car but then after shuting it off and putting the rest of it back together it has not flashed since. Wife is driving it today and is very happy to have heat. Found out from another forum that my car is actually an SLE. hmmm
Cool.

Well, after fixing the acuator everything has been working fine since. Until, today, my wife just called and said NO heat, nothing at all will come out. Not even if she trys to manualy turn the fan on. She said the display shows auto or fan on high etc but there is no heat at all. It was 5 degrees here this morning. I think it is 20 out now but whew it is going to be a cold ride home. Anyway, any ideas what could be causing this? She said the display is not blinking. I ask her if there was anything warm coming out the vents at all when she drives and she said no but I wonder if it is just the fan not working.
Thanks for any help/ideas...I will check it out more then I get it home in the garage.
Rob