thermostat control box linkage 'balljoint' busted - cause or effect?

krasuskyp · 04-13-2011, 09:51 AM

So my heat's been stuck on since turboPALOOZA '09 (on, except on cold days when I need it - then it's stuck OFF - of course), and I'm finally endeavoring to remedy.

I noted the passenger access 'door' on the side of the tstat control box between the seats was popped off.

Hmmmm.

Well gee, the ball joint fell off of the linkage - cool, just reconnect!

BZZZZT.

Reconnect, watch as heat is turned, and note it pops right back off.

Hmmmm.

The plastic ball joint end-link is cracked, allowing the ball socket to expand.

Soooooo, did 'this' cause the link to fall off? OR, is this the result of something else downstream in the system?

Any BTDT appreciated. For now, I'm going to give it a whirl via some JB weld and see, but I figure my luck is this cracked for a reason.

TIA ladies!

johnghini · 04-13-2011, 09:59 AM

Really easy fix.
1. Remove rubber gaiter on e-brake...just slide it off
2. Pull e-brake up
3. Unscrew plastic ball joint and screw on new one that you can buy from Pelican.
4. Try not to alter the location of the locking nut on the backside of the ball joint as you'll want to maintain the same adjustments you had prior.

If you rearward ball joint is broken, you can remove the pass seat, and unscrew the center console so it lifts out of the way to get easy access.

The ball joints just fatigue over time.

gumba · 04-13-2011, 10:05 AM

With it disconnected you should be able to manually move the lever up and down to work the heat. I would try that first and make sure the heater flappers are opening and closing easily. If the flappers are binding that would cause the ball to pop off.
I resigned myself to using it manually. It would shut off in cold weather and turn on full blast in the summer.

krasuskyp · 04-13-2011, 10:13 AM

Thanks for that info John - I feared (my luck) that it broke for a reason other than fatigue.

I'm gonna JB weld the sucker up for now.

Speaking of JB weld, you mention the ebrake handle... of course I JB welded that on not ever considering (typical) that I may ever need to remove that. Was pissing me off constantly popping off so it's slathered on there good now. Awesome.

Fortunately I got the joint off just by reaching down there thru the access door, and will be able to get it back on the same.

Still suspicious tho of why it broke, honestly 8-/...

krasuskyp · 04-13-2011, 10:16 AM

Thanks Harold - replied to John before I saw your reply.

I imagine if the flappers are binding they can simply be lubed yes?

So you're saying I can just grab that rod (I'm well rehearsed) and pull / push it with ease under normal circumstances? I think it seemed pretty tight but I didn't want to force it.

Time for lube inspection back yonder.

Funny huh on the failure mode - freeze winter / roast summer? Porsche Gods, bedamned! I'll have to determine an appropriate offering in hommage prior...

johnghini · 04-13-2011, 10:19 AM

It seems the little servo motors are pretty robust and don't turn too freely manually. It puts a fair amount of stress on that little plastic piece. Mine failed the same way as yours but I believe it's just a function of 25 year old plastic. My friend w/ a 88 had the same issue...seems very common and most likely the servo motor and all heating linkage is probably just fine.

krasuskyp · 04-13-2011, 10:29 AM

Cool tx, that answer is precisely what I was hoping for! Figured others might have BTDT.

Love these fixes, my fave!

CANNOT wait to remove the FIRES OF HELL from my interior (hot daze only)...

Ken911 · 04-13-2011, 11:06 AM

Quote:

Originally Posted by krasuskyp

Thanks for that info John - I feared (my luck) that it broke for a reason other than fatigue.

I'm gonna JB weld the sucker up for now.

Speaking of JB weld, you mention the ebrake handle... of course I JB welded that on not ever considering (typical) that I may ever need to remove that. Was pissing me off constantly popping off so it's slathered on there good now. Awesome.

Fortunately I got the joint off just by reaching down there thru the access door, and will be able to get it back on the same.

Still suspicious tho of why it broke, honestly 8-/...

common thing that breaks our sponser sells them for a couple dollars. Probably less than the cost of a package of JB weld

LOWFAT · 04-13-2011, 04:08 PM

Who needs heat, just remove the whole system!!!! You already rid yourself of the a/c .

krasuskyp · 04-14-2011, 05:01 AM

Ben oh Ben... I live in frigidass *CT*! Not balmy sisterfukkerentucky 8-).

A/C begone! Funny, I hacked out the last shred of A/C evidence remaining in my heap last night. Dremel'd out the temp control knob and installed my A/F gauge - came out saweeet!

JB welded the link last night but it was 2:40am by the time I buttoned up the gauge project and I'm here by 8am so the link will be endeavored tonight.

JB weld was free Ken - on the shelf 8-). Love that stuff heh heh. Not to mention our kind host would gladly ship me the $0.37 0.005oz bit... for $9.95 shipping! That's a case of Busch bottles!!! (oh the depravity of horrendous bier - love it)...