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-   -   How To: HVAC (Climate Controls) Broken Cable (http://www.focusfanatics.com/forum/showthread.php?t=293932)

nomind 07-28-2012 09:41 PM

How To: HVAC (Climate Controls) Broken Cable
 
I've seen several posts regarding broken vent selector cables, and I decided that when I did mine, I would document them, so that others would be able to try and do this on their own. On a scale 1-10, I would rate this about a 4.5, and installation took me about 1.5 hours, documenting, (and the one minor screw up).

First thing you need to do, is remove the radio, and the four bolts behind it (7MM I think).

http://i1174.photobucket.com/albums/...s/DSC06736.jpg

Pull the face plate forward, and start unhooking the electrical connections. You will need to disconnect the hazard switch first in order to really be able to get to the rest of the connections.

At this point, you can either unhook the selector knobs,so you just have them to deal with, or leave them connected to the trim panel. If you are replacing the whole thing with one from a junk yard like I did, I'd just leave them hooked up.

http://i1174.photobucket.com/albums/...s/DSC06741.jpg

Remove the lower dash panel underneath the steering column (8MM I think), and let it hang. The other end of the cables are close to where your right knee would probably be. They look like this:

http://i1174.photobucket.com/albums/...s/DSC06737.jpg

There are three mounting tabs that need to be released in order to remove the cables.

Here:
http://i1174.photobucket.com/albums/...s/DSC06739.jpg

And here:
http://i1174.photobucket.com/albums/...s/DSC06740.jpg

Once the tabs are released, the cables will just slide up and through the back of the dash area:

First one
http://i1174.photobucket.com/albums/...s/DSC06742.jpg

Then the other
http://i1174.photobucket.com/albums/...s/DSC06743.jpg

I pulled these apart, so if you just got the cable from Ford, this is how they work. There is a release tab at the top of the selector, and then the cable assembly will just pull away like a hinge.

Release tab
http://i1174.photobucket.com/albums/...s/DSC06744.jpg

Pulling away
http://i1174.photobucket.com/albums/...s/DSC06745.jpg

What the good cable looks like
http://i1174.photobucket.com/albums/...s/DSC06746.jpg

The new ones just clip straight back onto the selector lever

Lined up
http://i1174.photobucket.com/albums/...s/DSC06747.jpg

Back together
http://i1174.photobucket.com/albums/...s/DSC06748.jpg

Reattach the cables to the trim panel. This is where I had a small issue. The cables will only attach back to their correct location under the dash, and the selector knobs will only go onto one spot on the control panel. However, if you take the cables off, they will go onto the back of either selector knob. This resulted in my temp knob controlling the vent output, and vice versa. So I would recommend swapping one cable at a time if you need to. If getting them from a junk yard, just don't undo them from the back of the selector knob.

New cables into the trim panel
http://i1174.photobucket.com/albums/...s/DSC06751.jpg

New cables under the dash
http://i1174.photobucket.com/albums/...s/DSC06750.jpg

At this point, all that is left is to make you electrical connections back, put the trim back in, and reattach the lower dash panel.

mikebontoft 07-28-2012 10:06 PM

good work, I like this how-to. I'll see if we can put it somewhere.

roberted5 06-15-2013 02:09 PM

How do the knobs come off.I have the whole cable assembly but the knob just won't pull off.

The temp knob cane right off but the knob that changes direction of the air either is stuck or isn't supposed to come off?

roberted5 06-15-2013 02:53 PM

Quote:

Originally Posted by roberted5 (Post 4777554)
How do the knobs come off.I have the whole cable assembly but the knob just won't pull off.

The temp knob cane right off but the knob that changes direction of the air either is stuck or isn't supposed to come off?

Even though you get the whole assembly,knob is stuck like glue.It's much easier to leave knob in and detach by releasing two catches one on bottom side one on top.Do bottom 1st but be careful not to pry it too much,it's looks like it would break easy in cold weather.

Now for blowing out vents,if there is no debris then replacing cables doesn't fix anything for the new cables are hanging up.Contacts was lubed but something else is causing the door to bind up.

kkblparker 08-23-2013 06:24 PM

i have replaced this many times mine broke because the gears im my junction box are messed up if it is hard to turn may be the problem and will keep breaking the cables

clshores 10-17-2013 02:21 PM

Can someone provide the cable assembly part numbers for both the temperature control and function control cables?

Will make life easier to order when needed.

Thanks for the help!

chikn 12-08-2013 12:49 PM

Quote:

Originally Posted by roberted5 (Post 4777585)
Even though you get the whole assembly,knob is stuck like glue.It's much easier to leave knob in and detach by releasing two catches one on bottom side one on top.Do bottom 1st but be careful not to pry it too much,it's looks like it would break easy in cold weather.

Now for blowing out vents,if there is no debris then replacing cables doesn't fix anything for the new cables are hanging up.Contacts was lubed but something else is causing the door to bind up.

Just finished this job and the knob does come off. Bought the cable unit at a Ford dealership for $60. (yep Canadian prices![:(!]) You just gotta put a little force on it with a screwdriver. I also put a little bit of light grease on the slide for the diverter. Hopefully that smooths things out.


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