Did mine a few months ago in my 89 and I never could get the two halves to separate. Even with all the little screws apart, dismantled everything possible, and it was still together. I made the decision to carefully remove the old heater core and slide the new one in, after cleaning the anti freeze out of the duct work. I tried to split it while I had it all apart, and the seams were glued (like superglued) together. As I tried to split it, I was cracking the plastic housing, so I stopped.
Wrestled my new heater core in without damaging the fins, etc. Put it all back together.
I completely agree, the genius whom designed that collosal mess needs it shoved far into his arse.

You think once you get it off the fire wall is an achievement, bullsh#t. The fun has just begun.
If yours is like mine and you choose to go the same route as I, watch the bracket that holds the heater core in. The 2 tiny screws are a beeach to get out / in without splitting the case (no room, I used a box end wrench, a gear wrench would probably work). I dropped them into the duct several times before finally getting it all back together.
Have fun....
