The motor spins, but the airflow is so weak its hard to tell if its moving at all.
I can stick my finger up into the box and feel the squirrel cage spinning fast and I have tried both recirc and external air.

I just replaced the blower motor, heater coil and adjusted all the linkages on the air box.

Is this normal?

Mine blows strong out of the dash vents but not so much from the uppers. I wonder if your ducts are disconnected somewhere?

just pull the flex hose off the sides of the heater box and see how much air is there.

What I had to do to make mine blow any kind of air is to clean the top of the heater core. dirt.leaves and debris get caught on top of it and restricts the air flow. There are a few ways of doing this, but I just cut a hole in the side of the housing, and used a the long, skinny extension from a smaller shop vac. I cleaned it the best I could with that and then resealed the hole back up. Here's one of the write ups I used....
http://web.archive.org/web/20110703225529/http://www2.izook.com/?page_id=258
It loads slow so give it a little bit.

I just bought a lint lizard for eight bucks (as seen on tv.) to clean mine out, now I just have to find a hole saw the size of the floor plugs.

Wait a sec - the heater actually does not blow heated air through the dashboard vents!

I know that sounds crazy, but it is true - those vents only blow cold air with the air conditioning (if installed).

If your truck used to have air conditioning, it is possible that the removal of the air conditioning coil has opened up that part of the system which reduces the air pressure coming out of those vents.  Yes, air does flow out - but it is never hot air.

In terms of general heated air flow, you need to check to make sure you are getting warm air out the sides of the air box for floor heat and out the vents below the windshield for defrosting.

Lack of hot air flow is caused by debris buildup on top of the heater coil (not a problem because it sounds like you have opened up the blower box and probably discovered the leaves) or loose/disconnected heating hoses that run to the windshield vents.

I hope that this helps!

Im wondering if the replacement motor doesnt spin fast enough or if maybe the fan has been worn down somehow. I dont get any airflow anywhere.
Most likely I have a closed flapper in the airbox that I am not remembering is there. I think it is time to pull it all apart again and look.
Im just glad to hear that when working properly it will blow air out of the vents.
 

is your fan spinning the right direction?

is your fan spinning the right direction?

Maybe. Wouldnt the air be coming out the intake if it was running backwards, or is that not how a squirrel cage fan works.

Im swapping the engine this weekend, and Ill be under the dash, Ill try swapping polarity.

you should be able to see part of it from just looking but it will still move some air going the wrong way.

Mine was blowing really weak (no difference in fan speed between Low/Med/High) when I first got my samurai, here is what I had to do:

1: Pull the switch and had to re-solder the med and high setting wire back to its proper post since they had broken off.
2: I have to manually pull the flapper that shuts off the floor vents since the linkage is old and worn out.  It will not swich from floor to the defrost vents just by using the control on the dash.

I had the motor wired backwards! I am so F'n happy I dont have to pull that F'n box!!!!!!!!!
I guess squirrel fans only blow in one direction.
Thanks for the help!

glad you got it fixed.

What I had to do to make mine blow any kind of air is to clean the top of the heater core. dirt.leaves and debris get caught on top of it and restricts the air flow. There are a few ways of doing this, but I just cut a hole in the side of the housing, and used a the long, skinny extension from a smaller shop vac. I cleaned it the best I could with that and then resealed the hole back up. Here's one of the write ups I used....
http://web.archive.org/web/20110703225529/http://www2.izook.com/?page_id=258
It loads slow so give it a little bit.

Did you know that the iZook pages are also directly available? Please take a look at http://www.izook.com

Hope that helps.

-Eric

What Eric Sez!

The Izook Pages here at Zukiworld are the motherlode of information about the Suzuki Samurai (and TracKick)!

check it out!