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Improvement of heatercontrol shaft
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Posted by Theo ter Steeg (more from Theo ter Steeg) on Sun, 5 Jan 2003 15:55:04 Share Post by Email
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After having some problems with stiff controls of the air distribution, I decided to improve the white plastic shaft that controls the ventilation position as this seems to be the weakest link.
Before this I did lubricated the drums of the air distribution dampers according to bulletin 854-2205 but unfortunately this led to no significant friction reduction.
To avoid a new replacement of a shaft again or spending much time and money for a new heater box I tried to replace the cross hinges of the shaft by universal joints couplings and with success!! It works despite the friction. Also the hysteresis caused by the elastic deformation of the hinges is disappeared.

Here’s what you need:
Two universal joint couplings. I used an 3/8”and an 1/4” normally used for a socket wrench. And an aluminium disk of round 20 mm; 12 mm long.

Here’s what you need to do:
Cut off both ends of an old plastic shaft (part 4364279). Also the female T-interface and the male interface at the hinge line. This will be re-used.
Bore and grind the T-shape inside the left part of the 3/8” coupling and adapt (grind) the outside of the right part of the coupling so this will fit into the hollow plastic shaft. Glue the female interface inside the hole you grinded and the right side into the plastic shaft. ( left part is ready).

Saw a groove of 2 mm width, with a depth of max 7 mm, in the aluminium disc. Also make square pocket of 7 mm inside the disc for fixation of the disc to the coupling. (This depends naturally on the type and dimensions of coupling). Adapt the outside of the left part of the coupling so this will fit into the shaft. Mount the male T- interface inside the slot and glue this subassembly together.

General: Use a two components glue. The elongation of this construction may not exceed more than about 15 mm compared with original length otherwise it is much more difficult to mount.

This all cost me about 4 hours work and about 12 Euro for the parts.

Success!!


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