Help/advice replacing flapper boxes.
 

The prior owner of my 76 included everything needed to replace both flapper valve assemblies - right down to the hardware, gaskets and orange flexducts.

My problem is that I'm hesitant to start because the three studs that the boxes mounted on are rusted to the point where they don't have any discernable threads left - just a rusty nub and the remnants of a 10mm nut.

Question - if I snap off the studs during disassembly, what am I left with and what am I looking at in the way for replacing the studs.

Question two - how is the cable removed from the clamp with the tube guide in it?
I tried yesterday and it would not budge. Please don't say it 'just backs out' - mine did not.
Bentley was no help.

Thanks in advance,
Bill K

any help appreciated
Bill K

I recall seeing one or two threads on this in the past, choices were tack welding new studs or using a rivet nut stud.

Bill, is there room for you to cut some slits in the nuts with a Dremmel and small cutoff wheel? If so, that will help you remove them (along with lots of Kroil or whatever witches brew you like to use), and then you can clean up the threads on the studs by making a thread chasing nut (a groove filed perpendicular to the threads of a new, correctly sized nut.

'advanced search' is my friend.
For those who might also be interested here's the answer(s).
Thanks to those that replied.
Bill K

http://forums.pelicanparts.com/porsche-911-technical-forum/88272-heater-flap-box-mounting-studs.html

http://forums.pelicanparts.com/porsche-911-technical-forum/445144-heater-box-mounting-studs-broken-what-now.html

http://forums.pelicanparts.com/porsche-911-technical-forum/358562-snapped-studs-heater-flapper-box.html