well its done and Bill was right its not bad at all. I bought the acuator thru a friend AC Delco 38.00 including tax part # 15-71923 and there is NO green mark on it at all and it does not come with the threaded arm. The 2 screws in the HVAC were no problem. I got at the upper with a snap-on 1/4"swivel on an extension,no problem. The wire block on the HVAC no problem. The vaccum block BIG problem the nipples all broke off inside so I threw the block away and cut the lines off the HVAC and put them together with short pcs of vaccum hose, again no problem. The connector on the acuator no problem,long screw driver just like directions said. I then pulled the 2 screws from the heater core box, mine were 5mm not 7 mm but again no big problem. Then I dropped the cover about 4" and took the acuator off again no problem. The hardest part was getting the back screw on the acuator in. You can do it by looking thru the glove box under the brace and just start it by feel then use a 1/4" rachet on the socket. the old acuators main gear was cracked in 3 places ! It now works like new ! I can't praise you guys enough or this site. Everything worked out great ! I can't believe how helpfull all of you are mostly Echo ( good talking to you ) Bill and SSE ( good talking to you too ) You guys are the best and this site is one of the best I have ever been on. Thanks again Ech,Stan<Bill and any others I may be forgetting !
_________________

Looks like CVC answered that nagging question Boosty & I discussed - Can the actuator be successfully swapped without completely removing the heater core cover? YES! That really eliminates a lot of hassle. Good job, CVC! I'll have to update the procedures for doing this now. lol!

Nagging? I knew that when I swapped Bob'*. Pulling the cover out all the way..MISTAKE!

CVC...glad we could help. Ask more questions..we'll keep putting you to work and saving money.

Glad to hear of another success story

This is what is great about this site. Those that have done this and/or have the experience to diagnose and help guide in the fixing are here to help. And we continue to add to the understnading and knowledge base all the time.

here are some pics even though they are bad ones note 3 cracks
http://i29.photobucket.com/albums/c2...ts/gear011.jpg

http://i29.photobucket.com/albums/c2...ts/gear013.jpg