I removed the Dash in my 2008 XKR to have the leather redone, and while I'm in there, am going after the DuckBill. Followed the TSB instructions, and was able to get the duckbill off from the heater, but I'm confused looking at my old duckbill, the new one, and the instructions.

Here's my VIN shown on the removal instructions.


Removal instructions for my VIN


Here's a picture of my old duckbill that I removed (yellow part in above picture) and the new replacement part (updated version of the part # shown on the TSB).


Old and replacement duckbill

Then for what I interpret as all VINs, the TSB says you install the new part into the bulkhead?


Replacement part installation instructions

Anyone do this job before? I'm not sure how the new piece replaces the old. I believe bulkhead is another name for firewall. Is that picture supposed to be the inside of the firewall, and I'm supposed to press the new part into the firewall having the duckbill aim down on the outside of the firewall, and then when I push the heater back against the firewall, it's supposed to loosely fit into the wide end of the new part shown on the picture? I suppose I could alternatively just cut the heck out of my old one while it's out and just re-use it, though I did have to put a hole through both sides on the bill part to get it out with a tool.

On that note, any other seals I should replace while I've got this off. Getting that duckbill piece off the back was a PITA.

 

It looks as if you remove the old duckbill completely and just leave a hole in the bottom of the evaporator chamber and then install the new duckbill so that it is mounted under the bulkhead in the space between the bulkhead and the top of the gearbox housing, It will, presumably, almost touch the top of the gearbox.

It will be much easier to get at the duckbill should it block again, although, with an XKR, perhaps still not possible without a little dismantling. If it were me and I had a supercharger, I'd probably just leave it off.

Richard

 

Bulkhead is the term used in the UK equivalent to Firewall in the US.

The "new" (C2P21646) duckbill certainly looks like it's designed to fit into a circular hole in a metal panel and not a push-fit onto the outlet like the "old" (C2P16264). I must stress just my thoughts on seeing your photos and the TSB drawing - I've not done this myself.

Graham

 

Yes.
If I were you, I’d cut the lips off the new duckbill before installing it. It’s a modified design, but I’d want to be safe, and never have to deal with it again. Either that, or as you said, reuse the old one (with the lips cut off). In either case, make sure you’ve cut off enough such that there is an open hole, all the way through.

 

Thanks - the opening is an oval about 3/8" by 1/2", and it was presumably designed to be oval, so that even if it's compressed, you'd still have some space on the edges that would allow water through. So I suspect it should be good enough.

 

Kill duck Bill Vol 1.