Been watching this thread and hearing my wife's complaints for a couple of years, so finally spent some time on the subject. I still need the wife's approval after experience but the temperature reading is promising. I made three modifications at the same time, so unsure which have the greatest effect.
1) installed some 1 1/2" expanding foam between the blower assembly and the firewall, as well as around the wire harness hole on the firewall towards the passenger side. I'm least certain about the effectiveness of this since the foam was not fully expanded due to the low temperature in my workshop.
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2) Added a 3/32 Silicone cord to the groove in the Blower motor sub assembly where it 'interlocks' with the rest of the blower assembly. I had some extra cord left over from redoing the seal on my under hood fuse box, and it was the correct size. I don't recall seeing others try this, but it seemed strange to me that a proper seal (foam or rubber) was lacking on this junction.
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3) The junction between the blower assembly and cooler unit was overlapping plastic with some foam between the seam. The overlap was inconsistent and not very tight after 23 years so I just sealed it up with a single bead of RTV. I did carry the bead higher than what the photo shows, but didn't get all the way up, just focused on what was easily accessibly.
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Results so far) I drove it on the highway for 10 minutes at 70 mph with an outside temp of 35 degrees F. Climate system was set at 70 with outside air coming in. Passenger side footwell was consistently above 65 degrees and varied depending on how close to the passenger door (an subsequently how far away from the heater vent) I took the reading. I grabbed a picture right after I stopped and the foot well was still near 70. Ultimately I can't call this solved until the family Christmas road trip later this month and sign off from the wife, but I think the results are promising so far.
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