'95 Sahara, 1st YJ

It'll probably take multiple flushes but you'll probably always have a little bit of rusty water stain now. Someone in the Jeeps past used tap water it sounds like.
 
I might try something like Thermocure before I put in new coolant. I don’t think I have a major rust problem because there are no particles in the drained coolant, and there’s no overheating; in fact, the engine is quite slow to get up to temperature, even though I put in a new Stant thermostat last year.
 
While everything is apart, might as well improve the looks. The housing was gray and discolored; the metal bits rusty.

Before:

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After
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Also, I drilled out the broken rivets on this bracket, and found some bolts that fit perfectly.

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Looking good, nice way to get that heater box looking new again and fixing the bracket.

Did you just back flush the heater core to clean it out? I was amazed how heavy my oem core was from all the rusty crud and sediment in it when I had my heater box out. I just wound up replacing it.
 
I flushed the core multiple times with the garden hose from both sides. The water would flush clean, then at the end come out quite red/brown. I was considering just replacing it, but since it’s not leaking and I’m replacing the coolant on schedule I’m hoping it will last.

I had to open up the heater box and redo all the louvres. There was superficial rust and they were binding up. The resistance had caused part of the control panel plastic to break (not sure how I’m going to fix that) before I acquired the Jeep. Plus the foam on each door was completely disintegrating into dust.

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Yeah, looks pretty similar to how mine was. Most of the foam was pretty dry rotted and some surface rust on parts. It had a ton of small leaves and debris in it and in the blower fan. I cleaned it all out and spruced it up. Then resealed it with RTV and over all, it all works pretty well. Since I removed the A/C, i wasn't concerned about it being 100% perfect. I really only have had to use it to clear the windshield or to add some heat on a cooler day.
 
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