Dash removal to repair heater fan

[pi quattro]

the correct way to remove shear bolts is to drill through the bolt, just as you did.
they are not meant to be re-used.

Nightmare! I still need to figure out how to remove the remnants of the bolt from the dash. I think I need some sort of thread tapper.

Funny I posted exactly the same question on the German IG 16" forum a few days ago and was also advised to also:
Look at the windshield wiper mechanics,
consider installing those "double spurt nozzles" od whatever they are called in English (the thingies that squirt warter on the windshield) because it is easier when the dash is off
look for/take care of corrosion in the vent air intake area
look for signs of wear on the upper clutch pedal fixation
and possibly upgrading the power brake unit to a BMW one...

Wiper mechanics - check
Corrosion on air intake - check
Clutch pedal - check
Upgrade brake unit - slightly beyond my know how!

[pi quattro]

Did this a while back with the help of Dan Hotpod. Here is my thread https://club8090.co.uk/forum/viewtopic.php?f=4&t=106887" onclick="window.open(this.href);return false;

The thread starts as being a bit syncro specific but ends being relevant to all types. Hang on in there as it will be worth it in the end. Get your new blower from BW. Its not expensive and will now probably outlast your van.

That is a good guide. I think that my side vents only blow cold air meaning its an older version where the box containing the motor is sealed? And will need sealed again?

[CovKid]

Personally, and I'd echo comments about not faffing with motor and just fitting a new one, you might want to consider replacing wiper motor too. There is a chance I suppose that it may have been replaced since vehicle was built, but do inspect it and if it looks exceedingly old or shows any sign of wear/play, I'd swap that out too. A 25 years+ motor isn't exactly in the flush of youth. This is such a major job to do, you just don't want to do it twice so do consider it.

Also have a really good tidy up of wiring that may (over the years) have become spaghetti under there and if the existing fusebox is not really providing enough outlets, think about adding a secondary smaller fusebox so you can wire all the modern gadgets in properly and safely.

[New Kentish Campers]

Shear bolts:
I did mine buy using a sharp, small cold chisel and hammer on the edges of the bolts. A couple of taps loosened them enough to then unscrew them normally.
Once off, I filed the burred edges off them so as to avoid future cut hands and tears if delving under the dash for whatever reason and that was it.

And yes, I suppose you should fit new ones, but....

[chuggers72]

I'm doing this the moment and also had the issue of two of the bolts shearing off! Ended up drilling them out and tapping new threads. Yep I replaced the fan motor as it seem pointless to tinker with the old one and relube! I also replaced the resistor (as it was cracked) with a kit from Brickwerks for £15 (it comes with two replacement ones) - these have been mounted outside the fan housing. Like everyone else says, have a good look around for anything that needs sorting. I also:
- checked and greased up the wiper mech as it looked in good nick with little play;
- replaced the washer hose as it was brittle and cracked and replaced the nozzles;
- also replaced all the wiring and switch for the heater motor (thats was only about a £10);
- treated bit oif rust behind the heater box;
- sorted earth crowns;
- tidied up / sorted wiring for stereo etc;
- also, gave the heater box a good clean up, checked all the flaps and relined them with flaps with new foam to get a good seal.

In the process of refitting it all, got a few other bits to do as well including replace the bulbs on the dash console . Yep its a long old job but hey...just enjoy it!

[pi quattro]

New motor/fan arrived from brickwerks! Looks good.

I will add checking wipers to the list, washer pipes and all the wiring.
I don't have any regular grease, but a ton of copper grease, would that be ok to use on the wiper mechanism?

I'm doing this the moment and also had the issue of two of the bolts shearing off! Ended up drilling them out and tapping new threads.

I had to drill out the shear bolts and there is some of the bolt still in there! How did you tap out a new thread? Never had the need to do that before

[pi quattro]

Just thought too, whats the best to lubricate the speedo cable? Wd40? Whislt it's all off might as well give that some attention.

[ghost123uk]

Just thought too, whats the best to lubricate the speedo cable? Wd40?

I wouldn't use WD40 to be honest, it has it's uses but not for this IMHO. I find it dries up fairly quickly and goes sticky.

Most folks use any old grease, but this can / does dry out over time, plus it only "reaches" the top couple of inches. Personally I would leave it alone or if you feel you have to, use a dry lube such as graphite. The sort of stuff you can buy for lubing locks as per = a choice here. Thinking about it, iirc it is Kev who often mentions "GT85" which is a silicone based aerosol, that might be good and the aerosol propellent would allow it to seep down the cable before that propellent gasses away. Still, I would leave it alone (GT85 is also good for cleaning black bits, like your dash )

[chuggers72]

Pi Quatro - tapping a new thread is not too hard. Drill a 5mm hole throught the sheared bolt, then buy an M6 tap (cheap from Machine Mart or similar or even buy a set if you fancy some new hardware!). Thread the hole (theres a bunch of vids on utube to do this) - buy some new M6 bolts and hey presto! Just take your time doing it.

[pi quattro]

Dash off!
Looking at the heater box and there were a couple of clips around it but it also looks sealed?

Can't find any screws from behind the grill outside the van as per wiki?

Tied to split the box- not easy. Trying to undo the big bolts that hold the whole thing in, can't undo two of them!

Which route- remove bolts and whole assembly or try to split the casing??

[chuggers72]

OK - Ive been here so I'll try and pass on my new found wisdom!!

Firstly dont try and split it in situ - you wont get the top off as theres a screw at the back of the heater box that holds the motor in place. My van (a 1986) did not have any screws behind the grill as stated in the wiki - the only bolts holding it in are the six inside. Like you I could not remove two of the bolts holding the heater box in - well and truly rusted to the bulkhead. Even after a week of soaking with penetrating oil I could not budge them - they both sheared of. Its a case of drilling out and retapping new threads before you refit it. The clips would suggest it may have been taken out before but if theres only two who knows?!

When you get the heater box on the bench split it carefully between the tabs using stanley knife/leverage from screwdrivers - it will split eventually just take your time. Feels like you shouldnt be doing it but you got to!!

When reassembling the box - reseal it with Sikoflex or similar. Before you do though, test it to make sure motors spinning the right way - some have been known to be wired the wrong way round!

[pi quattro]

OK - Ive been here so I'll try and pass on my new found wisdom!!

Firstly dont try and split it in situ - you wont get the top off as theres a screw at the back of the heater box that holds the motor in place. My van (a 1986) did not have any screws behind the grill as stated in the wiki - the only bolts holding it in are the six inside. Like you I could not remove two of the bolts holding the heater box in - well and truly rusted to the bulkhead. Even after a week of soaking with penetrating oil I could not budge them - they both sheared of. Its a case of drilling out and retapping new threads before you refit it. The clips would suggest it may have been taken out before but if theres only two who knows?!

When you get the heater box on the bench split it carefully between the tabs using stanley knife/leverage from screwdrivers - it will split eventually just take your time. Feels like you shouldnt be doing it but you got to!!

When reassembling the box - reseal it with Sikoflex or similar. Before you do though, test it to make sure motors spinning the right way - some have been known to be wired the wrong way round!

Thank god, I thought I was going mad! I have the whole thing split, but I can't get it off, I also dont actually have a screwdriver that reaches one of the screws!!!

I was worried about touching the pipes and the heater matrix if I removed the whole unit.

Even contemplated removing wiper assembly or brake servo for better access!

[pi quattro]

OK - Ive been here so I'll try and pass on my new found wisdom!!

Firstly dont try and split it in situ - you wont get the top off as theres a screw at the back of the heater box that holds the motor in place. My van (a 1986) did not have any screws behind the grill as stated in the wiki - the only bolts holding it in are the six inside. Like you I could not remove two of the bolts holding the heater box in - well and truly rusted to the bulkhead. Even after a week of soaking with penetrating oil I could not budge them - they both sheared of. Its a case of drilling out and retapping new threads before you refit it. The clips would suggest it may have been taken out before but if theres only two who knows?!

When you get the heater box on the bench split it carefully between the tabs using stanley knife/leverage from screwdrivers - it will split eventually just take your time. Feels like you shouldnt be doing it but you got to!!

When reassembling the box - reseal it with Sikoflex or similar. Before you do though, test it to make sure motors spinning the right way - some have been known to be wired the wrong way round!

All done, all put back together bar the steering wheel and everything seems to be working!

Should be a note on the wiki advising what to do with heater boxes that don't have two screws accessible from the outside!

In the end I managed to just loosen off the whole assembly and tilt it forward enough to undo the small screw at the back. I didn't need to move any water pipes.

I never want to attempt that again!

[REGGAJ]

All done, all put back together bar the steering wheel and everything seems to be working!

Great, now head a few miles up the road and you can do mine too, anytime that suits you

[pi quattro]

All done, all put back together bar the steering wheel and everything seems to be working!

Great, now head a few miles up the road and you can do mine too, anytime that suits you

No problem, any time at all

It probably would help you that I had tried it before and figured out the pitfalls!

Check for screws holding in the heater box from the outside first....