A/C Evaporator box clip tips

[mthomas58]

Many ideas posted about clip removal and installation. Ice pick, needle nose pliers, dental floss, etc. I recently purchased a used box with one of the cover tabs broken. JB Welded it back on and was concerned that the force required to snap the clip back on would break the repair. I used two opposing ice pics to gently open the clip and install with minimal force. The repair held up and this method eliminates the violence. Can't be done with the box in situ but doing so risks tab breakage and clip loss. This method works great. Push the handles apart to unload the spring clip and gently slip over the retaining tabs then slowly release the pressure.

[tomphot]

Sweet.... will try that method next time

[MBAtarga]

I haven't had the unfortunate circumstance to remove those clips (yet.)

It appears that with the holes on each tab of the clip, it might be possible to use snap ring pliers to remove/install them. Has anyone tried that?

[tshih]

you'll find there is no room to insert any other tools in the tight space inside the smuggler's box. I lost 2 clips into the base of the box when it fell. Anyone know where I can buy 2 replacement clips?

[Rusty Heap]

tap off to the side with hammer/punch/flat tip screwdriver, slide them off to the side..

[Mitch Leland]

Originally Posted by Rusty Heap

tap off to the side with hammer/punch/flat tip screwdriver, slide them off to the side..

Rusty,

OK, now you've gott'em off, were you successful getting them back on the same way? The rear ones would be a stretch... Naturally you could always resort to safety wire. It boggles my mind that it's such a poor design. But then Porsche must have sub the entire A/C and heater system out to FUBAR Engineering anyway.

[WilsonTC]

Circlip pliers work well...(reverse them so they open when you squeeze).

[echecsqueen]

Got mine off today but after almost an hour trying to get even one back on I decided to wire the box closed and called it a day. Some blood was shed in the process.


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[dw1]

I worked on the evaporator box in my '87 a few weeks ago and came up with my own solution:

1. Make a hook from stiff wire that fits through the upper clip hole

2. Using the hook pull the clip so as to slide the clip to the side - don't try to pull it straight off. A long straight-blade screwdriver can be helpful to assist the clip movement.

This technique worked for me. Your experiences may vary.

[1979-930]

Originally Posted by dw1

I worked on the evaporator box in my '87 a few weeks ago and came up with my own solution:

1. Make a hook from stiff wire that fits through the upper clip hole

2. Using the hook pull the clip so as to slide the clip to the side - don't try to pull it straight off. A long straight-blade screwdriver can be helpful to assist the clip movement.

This technique worked for me. Your experiences may vary.

Ditto. Wire through top hole, place clip under bottom notch, pull up on wire while pressing on clip with flat blade screw driver.


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[wazzz]

Got rid of the clips and drilled 3mm holes in upper tabs then used small phillips screws to secure the cover. It is now easy to remove and put back on while in the smuggler box.

[GH85Carrera]

I did it the first time using long nose bent vice grips and lube the clips. They slide off the side with some wiggling. For sure use some string trimmer line or wire to tie on a retrieval system, they tend to vanish otherwise.

In the end, when I pulled my evaporator and the entire box, I drilled some small holes and put in a little screw instead of the clip.

We have to remember Porsche managed to air condition a car that was never designed to have air conditioning in the first place. Their AC engineers must have all lived in the mountains and they never tested the system in hot conditions. The condenser area is just inadequate without adding two more. With 4 condensers, you can get great AC.