Fixed our noisy AC/Heater fan and leaky duct work.

I have seen an evaporator cleaner wich might be worth a try i have never used it myself though.
http://www.ebay.com.au/itm/LUBEGARD-...=item1def32840

I was thinking of trying throttle body cleaner when i do mine lol

Thanks, ripper.

I had exactly the same gap and fixed it much the same. There was also a bit of seal coming out on the other side of the evaporator, but managed to just poke that back in to place with a screwdriver.

Should have taken you advice on removing the kick panel though, I dropped a screw down behind there while removing the fan housing and it took ages to get it back. lol

Found a cherry ripe wrapper in my ute after i bought it.

There's another thread on here that mentioned smell and how to eliminate it.
Good spray of Glen 20 was the answer, ( apart from vac manual hand cleaning ).

Set to fresh air next time you drive on home.
Leave aircon off, give box a good chance to fully dry.
Excess moisture will make it harder for glen 20 to kill germs that are the cause of this smell.

Set to recycle, cool, no aircon, fan set to medium.
give a few good squirt of glen 20 at the air recycle intake under the dash.
may need to do it a couple of times.

might be worthwhile setting to heat also and another squirt.
incase smell has somehow managed to take hold also in the heater box.
cheers