Heater Flapper cable, how does it come apart?

andyt11 · 03-22-2011, 05:17 PM

I'm investigating my stuck flapper box. After soaking the studs in penetrating fluid for two weeks I was able to get the box off the car without breaking any studs. However, I cannot release the cable from the box. The rusty end on the cable seems to be just that, a part of the cable. I assume it slips over the black painted tube on the flapper box. Is it a case of them just being rusted together? Or am I missing something?

Any tips for seperating without cutting? I don't really want to keep reefing on it either. The car is an 88, and pelican does not list the cable for this year. i havnt been able to dig up any pictures of cables like these. Any help appreciated.

DRACO A5OG · DRACO A5OG's Garage

Tap on the rusty metal tub and it should pop off the metal housing on of the flapper. ( may have rust welded a bit )

I replaced cable at ACE with some Nickle plated steel cable same OD, they keep it in the back. :-D

andyt11 · 03-22-2011, 06:05 PM

ok, so the rusty collar comes off the black tube that is part of the flapper box?

DRACO A5OG · DRACO A5OG's Garage

Yes, It provides tension for the cable to slide back and forth, if tool loose when you reinstall it will not fully disengage the flapper.

Just recently did this repair.

A tip on putting the lock bolt and nut back on use a needle nose vice to hold the cable near the nut/bolt to tighten it. if you don't you will inadvertantly break the new cable. Ask me how I know

A helper would be good to make fine adjustments under the car too

Gogar · 03-22-2011, 06:37 PM

If you can't get it or you break the cable, don't worry much; as mentioned you can replace the cable with 18 gauge (or maybe 16 gauge) plain steel wire from the hardware store. It's not a "fun" job, but not too crazy hard.

Although I just realized as I type this I only have experience with an early car that has ONE heater pull lever, not auto-heat or two separate levers.

andyt11 · 03-22-2011, 07:21 PM

I'm going to really try not to break anything, I have enough to do already!

NutmegCarrera · NutmegCarrera's Garage

Replacing this cable (one side only) last winter was a real bitoch for me.
I likely spent as much time doing that (alone) as I did on the disassembly and cleanup of all of the front end parts. Hardest part in my experience was threading the new cable in without destroying it. Any notes on how to properly affix the new cable to the lever? Darn near cut my fingers off doing this - and am afraid that mine was done 1/2 azzed. Surely isn't as pretty as factory, but I think it will hold.
No, I don't have any photos - was too disgusted to take any.

DRACO A5OG · DRACO A5OG's Garage

Just a note, you need hardened steel cable like the nickle plated one I found. The standard cable is just too soft, could fold and break.

andyt11 · 04-12-2011, 04:39 AM

So I have both boxes off the car and have decided to replace rather than try to repair them.

I still cannot separate the cable from the flapper box. We are sure it is supposed to slide off the round part of the flapper box right? I'm going to start using a bit of brute force there soon.

I don't want to cut the cables, they look like a pain to replace (I have enough to do already!) and there are no parts listed for 87 onwards cars.

javadog · 04-12-2011, 04:46 AM

Given the poor condition of the cable housing in the photo, I'd suggest replacing them as well. There's nothing holding them on, other than rust.

JR

andyt11 · 04-12-2011, 06:20 AM

Ok, tonight, I'm setting it on top of a jack stand and I'm going to knock it off with brute force. The cable slides nicely, its just that end piece that is rusted to crap. I have some POR15 so if I can get it apart I'll treat the end of the cable housing and paint with Galvcon. Should keep it from getting any worse. Car never sees water anyway.

Will pick up some new flapper boxes.

javadog · 04-12-2011, 07:05 AM

FWIW, I think the original cable housings have been superceded to part number 91142480401.

Pelican Parts - Product Information: 911-424-804-01-OEM

JR

Ramathorn · 04-12-2011, 07:45 AM

Ugh. I just replaced my passenger side cable and what a PITA, I elected not to do the drivers side even though i couldve as the cable/ glorified coat hanger is a little short if something (even though I bought both) happens ill be replacing them both with new ones. My advise is exactly what DRACO suggested from the new replacement type and the needle nose vise grip to hold the new cable in place.