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I have been lucky enough to be blessed with several heater box failures of late and I see a pattern developing. It seems that the heater box failure might actually be preventable with a little work. On both sides of the heater box there are motors(stepper motors) that control the blending of the temperature for that side of the car. directly under these motors are small plastic levers that act as stops for the blend motors which also keeps the notorious blend shaft from being overly torqued to the point of snapping.
What I am seeing is that these links paticular ly the one on the driver's side have been breaking which transfers the load at full open/close to the blend shaft which in turn eventually causes the shaft to snap in half thus rendering the heater box useless.
As further evidence of a problem here the new replacement links are heavily reinforced at the point directly across from the lever arm which seems to be the point of failure.
If anyone is under the dash of a 9-5(lower cover off, particularly the left side might also be specific to market as the box may be a wirror image in a right hand drive market) look up and you will see a small duct that attaches to the lower cover which is about 2.5 inches(65mm) square. if you look in this duct you will see a needle like devive sticking through the side of the duct. This is the blended temp sensor for that side. above that up in the heater box is the shaft that breaks(yellow shaft on the left and blue on the right) if you follow the shaft out of the heater box you will see a small electric motor mounted to the side of the box(blend motor) Between the motor and the side of the box should be a small plastic link(most broken ones have been green on the left and white on the right). This is the lever that is breaking directly across from the lever arm and usually is off completly and lying on the underdash cover when you pull it off.
I would be interested in hearing what other techs and DIYers are seeing here.
posted by 172.158.175...
, Fri, 25 Jun 2004 10:05:25
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