18 years back and many miles since, I replaced the Factory original Mode Actuator and heater core. Well, a couple of weeks back the replacement Mode Actuator failed. I ordered a new Actuator from Old Air Products. I figured even though the Heater core was still good, not leaking, I might as well replace it while I had everything apart. I ordered the new heater core from Rock Auto. I have the Heater Box assembled but I haven't installed it under the dash, yet. For anyone interested, I uploaded to my page, some pictures of the Heater Box, etc. I was able to remove the Heater Box from under the dash without removing the blower housing from the engine bay firewall or removing the hood hinge, as the shop manual lists to do.
You can JB weld that resistor together. To fix the vacuum valve, drill the rivet head off and sand the 2 sealing surfaces flat again. Use a mirror with fine sandpaper. The mirror will give you a flat surface.
You will need to drill and tap the rivet post for a machine screw. Use Loctite so the screw doesn't back out.
I have extra valves if you screw it up.
Russ, Thanks for the tip!
Forgot to mention that you will need to use high temp vacuum grease between the 2 halves.
Russ, thanks for the follow up on the required lubricant.