Well my a/c is leaking and its the evaporator. I am planning on pulling the box and doing it and the heater core next weekend, I started taking some parts off today to get a feel of where everything is and when doing some research saw a guy that replaced the vent doors near the ac evaporator by cutting the side of the box out. I understand that this isn't the best idea that i have ever had but I wonder if its possible to cut around the ac evaporator and drop it out without removing the dash? I have a plastic welder and putting the box back together isn't much of a problem. Someone please tell me this is the worst idea ever before i get bored and try it!

 

It seems like it would be just as much of a pain as pulling the dash out. I did mine and it wasn't that bad. I found a really good write up that I can send you when I get home if you want it. also if you want to do the heater core (which you should while you're in there) you need to take the box out anyway. Also, it's kind of a merit badge for 97-01 owners