My hot and cold adjustment cable is working fine, but at the end where it attaches to the heater core box, the lever broke. Can anyone tell me if the lever only can be replaced or does the lever come with the shaft. Then, to replace the shaft, do I need to pull open the heater core box to also replace the baffle that the lever and cable control? How much of a pain is this?

Thanks,

Scott

 

Can anyone help with this?! I'm in the same boat

 

Hey, I have not yet fixed mine, but I did get the entire heater box at a good price from Hawks. It is in the attic. I think that is the fix, replace the entire unit unless you can do a spot weld or something. I will get to it some time next summer

 

The cable connection point broke on my '87 IROC and I was able to pickup a replacement air-flap door at the wrecking yard. The metal where the cable connects is some sort of pot metal, so it can't be repaired. Changing the air-flap door was awkward but not impossible ... easier than than changing the heater core which is a PITA. If the connection point breaks again, I'll fabricate some sort of fitting out of steel or brass and silver solder it in.

 

How is the flap door attached to the heater box? How do you remove it without removing the heater box?

 

The door axle fits into holes top and bottom. It was so long ago when I did it, I don't recall the exact process, but I went to the salvage yard and removed a flap door from a wrecked Camaro which had an intact cable fitting. Problem on getting it out was that the cable connection couldn't be removed onsite, which prevented the door from being removed from the lower hinge point ... so I brought it home, put it in a vise and removed just the cable connector, then replaced the broken one on my car. So I didn't swap flap doors, just changed the broken pot metal part. The pot metal part is really fragile, and people with big boots have a tendance to hit it unless the under-dash plastic shield is installed. If it breaks again, I'll fabricate a replacement from brass tubing and sheet metal. So the easiest fix is to change the pot metal part, and avoid changing the door itself.

 

PITA?? I smell antifreeze when driving which leads me to believe the core is leaking. Not sure what you mean by PITA but I've heard you have remove the entire dash, UGH! Any other ideas?