Re: Has anyone disassembled their heater box?
I did just this back in December. To remove the rod from the flapper I took a punch and knocked it back through the box/flapper door. This was easier said than done. It also mushroomed the tip of the rod. I just took the rod to a bench grinder and smoothed it back out for re-installation. If I remember correct, mine was rusted pretty bad in there and it was a bear to get out. When you re-install it there is a flat side on the rod to help position it back in the correct location.
Patience. You'll get it. 
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1971 C10 SWB 2WD Driver 350/TH400
2003 Silverado 2WD NBS EC-Daily Driver
"Life is not easy for a boy named Sue."-Johnny Cash
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