Heater box removal and disassembly
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This shows condition of heater box where upper controls are located.
More detail of flap actuator.
Removal of the heater box from the bulkhead.
Coolant feed at the bottom of heater matrix.
Air flaps inside heater box.
Showing A/C connection to evaporator.
Close up view of holding strap for heater duct.
Hole for the flap bushing.
Showing crushed heater drain and drain pipe blocked.
Another view showing the missing shaft bushing.
View of flap no longer supported on bushing.
View of linkage to lower air flaps.
Lower flap being removed from box.
Heater box with original foam insulation.
Another missing bushing.
Heater box sections.
Recirculating flaps have fallen out of bushings!
Arrow indicate separation.
Heater matrix in the box showing the coolant connections.
View of the box with heater matrix still in it.
Heater box with foam insulation removed.
Heater matrix with coolant connections showing.
Disconnect the flap at this point (arrow) from inside the car.
View of the connection from inside the engine compartment.
Reassembly of heater box begins!
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Remove old foam from flaps.
More old foam removal.
You cannot remove this flap from the unit so work with it in place.
Making pattern for flap.
Cleaning the flap to ready it for foam installation.
Fitting new bushings for flap actuator rods.
Flap rod through bushing.
Foam with glue ready to mount to flap.
Flap with foam attached.
Another photo of bushing insertedd over shaft.
Non-detachable flap receiving new foam.
Foam attached.
Foam cutout ready for attachment.
Lower flap attached to box.
Lower flap with foam attached.
Another shot of bushing with shaft inserted
Pattern made for iside of outer box.
Areas covered with sound deadening foam.
Car Heat and Sound Insulation product I use.
Another shot of bushing inserted in unit.
Pieces cut out from patterns.
Heater matrix fitted to outer box replacing grommets.
Insulation fitted to outer box.
Save your patterns for future use!
Assortment of new heat and sound insulation ready to install.
Fitting control rods to flaps.
Checking position of flap levers.
Fitting levers to flaps.
Another shot for positioning of levers
Checking lever position.
Heater matrix anchor points.
Heater matrix anchor points.
Put sound deadening foam between matrix and box.
Fitment of grommets.
Fitment of gromments (inside view).
Showing the recirculating flap removed from car.
Recirculating flap removed from mounting bracket ready for foam and bushings.
Recirculating flap mounted to bracket with new bushings and foam.
Recirculating flap showing backside with new foam.
Opposite side of flap also needs foam.
Ready to be mounted in the car.
Fit the flap to the inside of opening.
Flap mounted.
Grill mounted in place.
Actuator now needs to be serviced before being refitted.
Inner heater box assembly returns to car
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Checking that sealing edge is flat and shaped to car body.
Overall view of complete inner box fitted to car body.
Closeup view.
Closeup view.
Outer heater box assembly returns to car
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Seam sealant spread on sealing surface to make airtight seal.
Checking fit.
Anchor points on bottom ledge.
Anchor points on bottom ledge.
Nuts fitted to outer box.
Overall view showing hood latch attached.
Actuator strip, clean and reassembly
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Remove cover from actuator motor.
Push spacers out of mounting grommets to remove the cover.
Remove grommets holding cover.
Removing grommets.
Removing grommets.
Showing actuator with cover removed.
Removing brushes from motor by sliding retaining clip off.
Removing clip.
Removing clip.
Another view of removing brushes by sliding retaining clip off.
Removing clip.
Removing ground screw from motor assembly.
Showing motor with brushes removed.
Brush spring removed.
Brush spring and brush removed.
Removing second screw from motor assembly.
Armature removed from assembly.
Showing wire contacts.
Gearbox.
removing the wire through cover plate.
Removing gears from gearbox.
Removing second gear.
Removing drive shaft and gear.
Coverplate showing contacts.
Motor showing old grease.
Old congealed grease.
Drive gear and gears cleaned..
Ready for re-assembly.
Clean contacts for re-assembly.
Fitting brushes and springs.
More fitting of brushes and springs.
Low temp lightweight grease for lubrication.
Gear and shaft fitted to body.
Second gear fitted.
All three gears in place with wire through base plate.
Showing correct location for feed wire.
Grease shaft bearing of unit.
Motor attached to plate showing brushes with spring ready for the clip.
Fitting brushes.
Fitting brushes.
Heater motor rebuild
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Armature showing the commutator that has been cleaned.
When you remove the armature, I used an old steering seat to maintain the magnets while the armature is removed.
Magnet ready to receive the armature.
Armature fitted to magnet.
Bolts inserted into case.
Bolts through case to receive brush carrier..
Brush carrier mounted to bolts.
Springs mounted to bolts.
Rear part of case mounted to the motor.
Bracket that carries the motor ready to receive the rubber mounts.
Rubber mounts installed in bracket.
Inside of bracked showing mounting nuts.
Nuts started on mount.
Motor inserted on mounts.
Another view of mounts.
Motor and mounting plate in vise ready to test motor.
Positioning fan.
Mounting screw for fan on motor shaft.
Another view of fan mounting screw.
Clearly showing fan mounting screw.
New flange gasket made.
Motor mounted in swirl cage.
Motor mounted showing mounting points of flange.
