Air conditioning help-I broke something

[Steve 82SC]

My evaporator fan was noisy, so I replaced it. Everything was going ok (not including back & knee pain from leaning into that smuggler's box) and then I hit a snag. Upon reassembly, the piece of copper tubing that serves as a sleeve for the thermostat wire got kinked. Eventually, from trying to fit it into the evaporator fins, it cracked. Since I was feeding it into the top of the plastic box, I don't think I ever lined up properly with the original spot that it was seated into.

Theoretically, here's what I want to do - I figure I can find a piece of copper tubing al Lowes, etc. Then, my plan was to cut a much longer piece than is necessary, say 12 inches. Then I'd feed the crimped end down through the original path through the evaporator fins while leaving enough space between the cover to get my hand in there and work the other end through the hole in the top of the box. Then, after seating the top of the box, I would cut the tubing to the proper length and flare the end as the original was so as not to allow it to fall through the top of the box, eventually re-inserting the thermostat sensor wire. Does this seem plausible? I'm sure someone else has had a similar problem....it's just a ***** working in there while trying not to be heavy-handed.

Naturally, all the foam, hose clamps, and air-duct tubing disintegrated....easily replaced at Lowes or Pep Boys.

Thanks,

Steve

Steve

[kuehl]

Steve,

The brass sleeve, for the thermostat's aluminum sensing tube, serves as a protective cover, however you don't need it though its nice to have. The depth that the aluminum sensing tube sits in the evpaporator's core is somewhat crucial; it must be deep enough to sense only the evaporator's core temperature. If you don't go deep enough or if you go below the evaporator then you can be sensing air temp rather than evaporator temp. You can measure from the top of the evap box to the center of the evap core to figure your depth.

I think you would probably find a thinner wall diameter brass tube at hobby store. If you have a wall that is too thick you won't be a quick response for the thermostat on off function. You can figure the length of the brass tube is typically about 4".

Don't cut or bend the aluminum tube. It is filled with refrigerant gas, so the gas expands and contracts to turn on and off the thermostat, you can read more about it here:
http://www.griffiths.com/achelp/achelp4.html
under the subject The AC Temperature Switch - An example in detail with a typical 911 Porsche

[ruf-porsche]

Hey Steve

If you need any help with your A/C give me a holler. I have a vacuum pump and gauge set.

We both live in the same city and drive the same year PORSCHE

[kuehl]

Originally posted by ruf-porsche
Hey Steve

If you need any help with your A/C give me a holler. I have a vacuum pump and gauge set.

We both live in the same city and drive the same year PORSCHE

Go Yankees!