Heater core issue- new heater/no heat- FJ62 (1 Viewer)

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Joined
Jul 1, 2015
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Location
Austin Texas
So I replaced my dash heater core 6-7 years ago, the old one was leaking, I got a new one, don't remember who from, had the outlet pipes brazed on to eliminate the C-clips (saw in it suggested in some thread), install went ok, total PIA. tho. No more leaking old core, I thought all was good to go It seemed to work, however, living in south central Texas at the time, I really hadn't used the heater in severe cold weather. Long story short, on a trip experiencing very cold weather, I found out it wouldn't blow hot or even warm air. Since then, I've "burped" the system several times to no avail (I replaced the radiator/thermostat/water pump a 1-2 yrs or so ago, burped it again, no change). I've replaced the heater valve to eliminate it as a suspect. I've opened the dash at least 2 more times checking that the heater flap/gates are going the right way, vacuumed out the evaporator and blower. Tonight on the way home, 38-40 degrees outside, cardboard covering half the radiator, recirculating the air in the cabin, temp gauge where it should be and the front heater had no discernible heat, rear heater hot and toasty. Further, the inlet/outlet pipes were so hot you couldn't hold them.

My questions- the foam that helped seal the heater core/AC bypass gate (in between the evaporator and heater core) had/was deteriorated to the point I had to vacuum it out and remove it, and I did not replace it. Is it possible that removal is allowing so much air around it that it's not heating it?

Or has so much sludge over 5 years accumulated that it's blocked the newer core? I can feel the core, inlet/outlet pipes, and they're all getting so hot you can't touch them, in the dash and in the engine bay. The rear heater works fine and always has, it gets good and hot.

I've posted regarding this years ago and I'm still baffled to say the least. Any insight would be greatly appreciated
 
how is the air flow out the vents?

if both pipes are hot, the core is hot
 
I'm going to find some foam tape and seal up the heater core/AC diverter flap and button it back up and see if it helps.
 

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