So the next step is going DEEP...Time to pull apart the dash and see if there is an "apparent" issue that you would not otherwise see. I didn't read back through the whole thread but have you completely flushed out the heater core and system with the coolant cleaner (acid basically) stuff? That may be the best bet for you. I am starting to have a few issues with my truck where if it is cold outside (say below 40*) the heater only puts out luke warm air (measured at the heater vents at about 100*) regardless of how long the truck runs. However on days like today where it is almost 50* at 6am (odd for this time of year) she was running like a champ when I went out to warm up the truck for work.
Most all the hoses have been replaced in my setup so there is no blockage anywhere unless in the heaters. The head was done about a year ago so there should not be any HG issues (no other indicators as well of HG issue) and the temp gauge never really reads above half or maybe 2/3rds at warmest.
So for me that means that I have two paths;
1. pull the heater lines and "flush" the heater core using the phosphoric acid stuff
2. pull the dash and clean EVERYTHING out from the heater core, AC condenser, and blower motor sections under the dash.
The second is going to be the most time consumptive but may lend to other items being taken care of like; wiring cleanup, debris removal, new dash cap to cover up cracked one, proper mounting of stereo to dash, etc.
Most all the hoses have been replaced in my setup so there is no blockage anywhere unless in the heaters. The head was done about a year ago so there should not be any HG issues (no other indicators as well of HG issue) and the temp gauge never really reads above half or maybe 2/3rds at warmest.
So for me that means that I have two paths;
1. pull the heater lines and "flush" the heater core using the phosphoric acid stuff
2. pull the dash and clean EVERYTHING out from the heater core, AC condenser, and blower motor sections under the dash.
The second is going to be the most time consumptive but may lend to other items being taken care of like; wiring cleanup, debris removal, new dash cap to cover up cracked one, proper mounting of stereo to dash, etc.