Gday all - as the subject says - the heater swtich won't go to recirc and remains on fresh the whole time. is it the switch or is it just better off getting a new switchbox?

Hooroo

is the switch physically stuck or won't it go into recirc?

check the flap that controls where the air comes from isn't broken, you can reach up from behind the glove box and if it swings freely the lug the control arm connects might be broken.

its way beyond common for the fresh/recirc flap to fail where the shaft goes through the side of the airbox, feel around in the passenger side footwell for a square-ish opening, and you will be able to feel a flap inside that moves freely

my advice? learn to live with it, either wedge it in the "recirc" position or leave it on fresh, the same flap has been in use since the XD's, and has been a common problem since then.....

i dont think the flaps or heater boxes are available new anymore, and it's like winning the lottery to find one at a wreckers that isnt broken, plus theyre an absolute **** to fit without ripping the dash out