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Unread 11-08-2012, 09:57 AM   #1
tecumsa
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Heater problem on '97

I know the problem, and the fix, but wanted to see if anyone here has an idea why it's happening so often, and if there is a better fix than what I've been doing.

When you change the air direction to the main vents (2nd position on the slider) an actuator moves a plastic link that moves the deflector door. That link keeps snapping where it connects to the deflector door. I've replaced it 3 or 4 times, and have to do it again.

I have no idea what happens to the little piece that breaks off, but I'm betting those pieces will start causing me problems some day as well, but removing the box is one major bugger that would keep my baby out of service for a long time (and possibly beyond my skills).

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Unread 11-08-2012, 10:01 AM   #2
TJSE1997
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One of mine was broken before and it has more stress on it if you change the vents while the air is on high. I turn the air all the way down to the first notch and then switch vents

1997 SE with 4.5" of lift on 33's
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Unread 11-08-2012, 12:33 PM   #3
Jonny Jeep
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Since breaking one of mine with the fan on high, I too turn the blower down to the slowest speed before changing the vent controls.
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Unread 11-08-2012, 12:51 PM   #4
tecumsa
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Hadn't considered that as a possibility, but considering how thin the part is that makes some sense.

Do you guys leave the broken part in the box, or do you have an easy way to get it out?
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Unread 11-08-2012, 12:57 PM   #5
Jonny Jeep
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I pulled the broken shaft out with a self tapping screw and the tiny bit that broke off, the retaining tab, is either still in the box or has been blown out of one of the vents. As it's small and plastic I suspect it's been blown out.
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Unread 11-08-2012, 12:58 PM   #6
tecumsa
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thanks
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Unread 11-08-2012, 04:17 PM   #7
TJSE1997
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I used a 3" deck screw

1997 SE with 4.5" of lift on 33's
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Unread 11-13-2012, 03:29 PM   #8
tecumsa
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Quote:
Originally Posted by TJSE1997 View Post
I used a 3" deck screw

1997 SE with 4.5" of lift on 33's
How did you use a deck screw to replace the plastic connector? I've been trying to figure it out to no good.
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Unread 11-13-2012, 05:30 PM   #9
TJSE1997
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I pulled the broken piece out with it

1997 SE with 4.5" of lift on 33's
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Unread 11-14-2012, 01:26 PM   #10
deadbiker
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My 97 takes in leaves due to the cowl being more open than other years.Dig around inside the box,see if its packed with leaves or other debris that will jam the doors and break the levers.as for the deck screw extraction method, crawl up under there and screw directly into whats left of the broken lever.when you have a good couple of threads in,you should be able to pull the broken piece out(with some force) good luck!
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Unread 11-14-2012, 04:29 PM   #11
tecumsa
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Got it done. Just used a screwdriver to break it, then a paperclip to push the other end through. PIA task when you can't see what you're doing, and have to do everything by feel. Haven't done that since Tracy in high school.
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