Currently my truck HVAC is not working properly. The air blows cold and hot as I turn the temp dial and I can change which vents the air comes out of with no problem. The blower motor works fine. I already pulled it to check. When the HVAC is on I can hear all kinds of air movement up inside the dash, but hardly anything comes out. I pulled a few of the solenoid actuators to check and see if they worked and all the ones I could get to without pulling the entire dash work fine. So I determined that I am going to have to pull apart the duct system to find and fix my air flow problem.

I have the service manual and the haynes manual. I have pulled every bolt and screw listed in those and every other one I can get to on the dash. I have disconnected all the connectors attached to the dash. I have removed every panel on it. I have also lowered the steer column and removed the steering wheel. I cannot get the dashboad to come off it is stuck quite solid on the driver's side.

The drivers mounting plate (not sure if that is the correct name) has a spot weld on it. I am wondering if some retard at the factory spot welded the driver side mounting plate in place to make easier for him to install the mounting bolts that attach it to the frame. The passenger side is held up with a small hook in the mount that slides into the frame, the driver side does not appear to have this feature. Below are two pictures of the mounting plate with the spot weld. What could this weld possibly be for? I can't see any reason for it to be there.

I am about to start drilling out the weld, but I don't want to mess something up that I can't fix. Any help or advice you have would be appreciated.

 

REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.
Disconnect and isolate the negative battery cable.
Remove the left a-pillar trim.
Remove the instrument panel top cover.
Disconnect the headliner wire harness connector located at the a-pillar.
Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
Remove the left cowl trim panel.
Remove the steering column.
Remove the two bolts (3) that secure the steering column support bracket (2) to the instrument panel (1).
Remove the park brake release handle actuator rod.
Disconnect the instrument panel wire harness connector (2) located above the brake pedal from the bulkhead wire harness connector (1).
Remove the instrument panel drivers side bezel.
Remove the three bolts (3) that secure the left side of the instrument panel (2) to the dash panel (1).
Remove the floor console, if equipped.
Remove the air bag control module cover, if equipped.
Disconnect the air bag control module electrical connector.
Remove the two bolts (2) that secure the instrument panel (1) to the center of the floor panel.
Remove the right cowl trim cover.
Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors (1) located on the right side of the cowl panel (2).
Disconnect the antenna coaxial cable connector (1) from the radio coaxial cable connector (2) located on the right side of the cowl panel.
Remove the one bolt (2) that secures the instrument panel (3) to the HVAC housing (1) below the glove box opening (4).
Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover (4) from the instrument panel (1).
Remove the right a-pillar trim.
Remove the three bolts (5) that secure the right side instrument panel bracket (2) to the dash panel (3).
Remove the four screws (2) that secure the instrument panel (5) to the top of the cowl panel (1).
Remove the two bolts (4) that secure the instrument panel to the top of the cowl panel.
With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
If required, remove the four plastic screws inserts (4) from the top of the cowl panel.

 

See if this helps. It has pics also which helps a lot

How to remove the dash

 

Thanks for the link Weedahoe. That guy mentioned two hard to see bolts attaching the steering column support to the dash. I thought I got them all, but I went back in to look again and there they were. I removed those and the dashboard came right out.

Still not sure why that spot weld is there though, there is nothing that attaches to the mounting plate there. The guy who posted pictures on your link has a spot weld on his too in the same place. Just weird.

In my case the problem with my HVAC was that the recirculation door had broken at the hinge and fallen over the top of the blower motor inlet, so almost no air was getting into the HVAC system.

 

I just did this to replace my heater core not fun. I painted the frame while i was in there.