reconnecting heater flap cables

[Waynard]

Hello Guys,

OK - please do let me know if this has been discussed is documented elsewhere.

Today I've found that our 2L Aircooled heater cables, leading to the pods, have been cut just short of the pod arms.
I knew the control lever was not opening or closing the flaps, but assumed there were no cables under the van – so was surprised to see the cables under the van.

I have purchased a new set of cables to give the middle lever a purpose.

My question:
Is there a trick to removing the old cable, to allow easy installation of the new cables.
The cables travel down a pair of outer tubes (blue and white tubes), is it just the old trick of attaching cord / fishing wire to the cables being pulled out and then use the wire to guide the new cables back through? Any tips?

Also how do the cables attach the arms on the pods? I've seen clamps on JK, does anyone have a photo of them institute?
Thanks
Leonard,

[CovKid]

In my experience cables are stiff enough to just be pushed through, particularly if existing cables (although short) still move in the sleeves. Plenty of grease and gently feed them through. The other trick is to chock-bloc the remaining cable to extend them to pods. All bug owners know this one.

[Waynard]

In my experience cables are stiff enough to just be pushed through, particularly if existing cables (although short) still move in the sleeves. Plenty of grease and gently feed them through. The other trick is to chock-bloc the remaining cable to extend them to pods. All bug owners know this one.

Thank you,

I will take a look today, I have a feeling the existing cables have jammed, as I was unable to pull one through, that said I was using my hands (I will try again with some grips).

Any guidence on the mechanics of connecting the end of the cable to the pod arms?

[CovKid]

Normally cables are held using a screw but you can connect in whatever way works to be honest. Remove the connecting sleeves from pods so you can access the flap and set cable so flap is just fully open when lever is at maximum travel - that way you won't put strain on the cable. Tighten then refit sleeve.

[bigherb]

Pull the cables out through the bulkhead and the front grill you will get an easier routing to pull them out and push them back in.
If they are still stuck check where the have been cable tied to the chassis if the ties are done up to tight they will crush the outer sleeve trapping the heater cable. There is is cable tie above the petrol tank which is often the culprit and a pig to get to.

[Waynard]

Just the advice I needed, thanks chaps.

I will report back with my progress, I'll take plenty of photos (I always do), and if helpful write a wiki for changing the cables.

[Waynard]

Pulling the rubes through the front grill, is a great tip, nearly completed the N/S cable

[LeeCarey]

Hi All, how did you get on with this. Looking to do both cables this weekend. Take long? Any snags? Did you get plenty of pics

Cheers for the advice and thanks in advance