Jammed heater control

[AlBundy]

Well not fully jammed, just jammed together. I can't move the top 2 levers independently, they both move at the same time. It feels mechanical just behind the controls but I can't get access easily. Do I need to take the whole dash off or is there another way? I don't want to force plastic and break it as I imagine that is more difficult to replace.

Any other suggestions welcome.

Al

1986 LHD 1.6 Diesel

[simonmarsh]

You can access a limited amount by removing the stereo I seem to remember

[Jim San]

Very carefully remove the slider handles and fan controller, very very very carefully pry the plastic facia off at the corners. You are right ti be cautious as the lugs do snap easily.
Mine has a screw to them remove the front

Remove the ashtray also as it also gives a hit of access

[AlBundy]

Thank you, have managed to get the cover off.

It looks like there is a small wire that goes through the top lever and down through the middle lever to the metal plate that separates the top two levers from the bottom lever.

The wires scrapes the metal plate which makes an awful noise.

Is this supposed to be connected like this?

[Jim San]

It's come out of its seating position.

[Jim San]

It's come out of its seating position.
That square z bend is supposed to be in a horizontal position with the middle section of the z in the hole of the lever. It's come all the through and touching the lever below - push it back up and secure it
Compare it to the other one, it'll be clearer to under, but the main part of the cable will also have a place to sit so as to maintain the tension, its a clamp type assembly

[Jim San]

You've lost all 3 lever knobs, they are available, mick at nw vw usually has some

[AlBundy]

Thank you for the guidance.

The wires goes through the top lever down to the second lever which means that the top two levers are always linked together, I can't adjust the temperature independently of the direction adjustment (directed to clear window etc).

Not to mention the constant bending of the wire is surely going to make it break?

Is that really how it should be?

[Aidan]

nope it ain't set up right

the cable on the left is the heater valve control, which is the one that fails usually and bends instead of move the actual valve on the hot water inlet down the side of the radiator, and should be on the second lever - when it is fully extended to the right for max hot it doesn't have a great route back into the cable outer and can easily get bent and not close the valve completely, so always warm at minimum, okay in the winter, not good on a long run this weekend

the top lever should be attached to the flap on the left side of the heater box which controls fresh air or interior recycled heat (and cold when the valve on the left is closed)

and the bottom lever should be attached to the other lever on the left side of the heater box that allows air to come out of the windscreen vents or other vents and centre foot warmer outlets

I might have these last two the wrong way around I don't have a three lever set up in my van, I have four (rear compartment walk through heat supply) so slightly different set up

so you need to find out what's happened to the cables from the left side of the heater box and which one is which

Someone has been in there by the looks of it - you are almost into dash out to sort it out properly and if RHD afaiaa the heater on off cable is only available from Brickwerks -

with the ashtray out you should be able to disconnect the cable and then check if the valve works, be aware that sometimes valve has seized and the lever arm on the valve moves but the internals of the valve don't, but valve is cheap as is cable

it's possible you are missing cable clip or clamps for one of the cables/levers, brickie still has a very few of the clips but the clamping plate is nla I believe if you find you are short of one again ask Mick or put up a wanted, I might have a spare odd one in one of my boxes of bits/fittings

[Jim San]

Thank you for the guidance.

The wires goes through the top lever down to the second lever which means that the top two levers are always linked together, I can't adjust the temperature independently of the direction adjustment (directed to clear window etc).

Not to mention the constant bending of the wire is surely going to make it break?

Is that really how it should be?

Has it always done this or just started to happen?

As improbable as it may sound, the top line has become stiff to operate (as Aidan mentioned), broken free from the clamp and forced its way through the mounting hole and jammed itself in the one below.
There could be no logical reason anyone would want to join them in this fashion