Recirc flap repair - Saab 9-3SS Bulletin Board - Saabnet.com
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Recirc flap repair
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Posted by MarkusJ [Email] (more from MarkusJ) on Fri, 23 Jul 2010 13:18:34 Share Post by Email
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I decided to try and repair a broken recirc flap motor. Removed the glovebox and the remove the 2 Torz headed fixing scres. An L-shaped tool is needed due to lack of space. Opened up the case which is held together with a few integral clips. It was evident tha there is a gear missing 2 teeth. The servo has no limit switch. What happens is the ACC unit senses increased current when coming to a limit and the motor goes in short circuit which causes a force on the teeth at each end position. Unfortunately it is designed so that the same teeth are under force at each end of travel. Of course the direction of force changes by 180 degrees.

The faulty gear is a double gear wheel having a bigger gear with 25T and a module of 0.6. A suitable gear is available intended for RC cars from
Tamiyalta under the set SP-477 for a few dollars. The alumium gear wheel must be modified by drillin away the lock nut collar from the outer side and the support collar from the cup side. Next the faulty gear wheel is mounted into a drill chuch and the broken gearwheel is turned away with a file until only the middle flange is left. This flange will fit the cup side of the new gear wheel. The joint is filled with epoxy wiht the aim to creat a form locking join as the POM (Acetal) of the smaller gear doesn't adher properly.

Finally the fixed gearwheel is installed back, cover on and motor in. Complete procedure should be possible in 2 hours.


posted by 89.166.101...


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