I am in the middle of rebuilding the A/C system on the trusty old 240 wagon. Thanks to Art Benstein's illustrated instructions I have removed the dash and taken the center console apart to get at the blower motor, which is also going to be replaced during this job.

As for the A/C work - I have disconnected the the lines on the TXV valve input and the refrigerant return side. The evaporator unit is sliding back and forth about and inch but it refuses to come out the right side of the A/C ventilation box. Art's blower motor instructions don't address this particular problem.

I must be missing a trick somewhere. Anyone out there know what might be holding the evaporator back? I attached pictures of it in the box and in it's slid-to-the-right position. I also attached a picture of the vacuum tee that sits above the blower motor housing right on top of the wires to the motor speed resistor. Looks like those wires can get pretty hot! I will have to put an insulating spacer in there when this all goes back together.

And, while we are on the A/C subject - what is the best stuff to use to seal the evaporator box back up when this goes back together after and clean/flush/inspection? The black gooey stuff sure took a lot of Goop to get off my hands!
Is that just butyl rubber caulk?