Just an FYI: you can easily repair the one you have. You'll use a small-diameter metal rod to replace both plastic pins. (It can be a slightly smaller diameter than the plastic pins.) Cut it to the length the flap would be if it still had both pins intact, end-to-end. Cut off the one remaining plastic pin on the flap and grind/smooth out the areas where the pins used to be. Then epoxy the rod in several places across the length of the flap. The next morning test-fit the flap and trim the ends of the rod if it's a little bit too long. Make sure it has free movement to swing.
Last year when I replaced my evaporator and blower motor, I did this fix and it's been working perfectly. Much stronger than the original design with the plastic pins, too.
Oh! Good call. That's an awesome fix! I'll give it a shot. That will very slightly move the pivot point, since the rod will sit slightly "lower", but I don't think that will be a serious issue. Thank you for the suggestion!
Yes, it'll sit slightly lower but it will still work fine. Before you permanently epoxy the metal rod you can tape it in place to test-fit it and make sure the flap will swing properly.
I ended up fixing mine slightly differently than you suggested---I dremeled out a channel, then dropped the metal rod in there and covered it all with a bunch of epoxy:
Thanks again for the suggestion! I hope that this fix is useful to someone else too.
