Heating and Bowden Cable Woes

["Bhatti, Mohammed" <MOHAMMEDB@iadb.org>]

It is interesting how one learns from ones mistakes. Take my example. 

Over the weekend I decided to finally figure out why on my 88 80q, the
temperature control flap did not rotate fully. I have the manual a/c head
with the three rotary switches. So I popped out the radio, the dash switches
and then the center console. I had previously dropped the glove box and the
drivers side shelf. A few months previously in frustration, I had pulled on
the bowden cable from the temp control flap to try and make the flap open
and close thinking that there was a problem with the flap and not with the
head. Well, in doing so, I had pulled the cable out completely from its
mounting on the heater plenum.

Ok, so I'm back again trying to figure out why the flap will not open/close
for hot/cool air. I've examined the Bentley and the way it describes how the
cables fit on the plenum and how the plenum is positioned. I finally figure
out that the Bentley is wrong in describing how the plenum sits behind the
center console. Also, if this particular cable is yanked from its mounting
on the plenum, than it appears that the only way to put it back in place is
to take out the entire console and the heater core (which would require
discharging the AC). Btw, it's real tight in behind the center console. My
hands are all scracthed from the experience.  So, I look at the head and I'm
still trying to figure out why the temp control switch will not turn fully.
Again, I'm thinking it's got to do with the cable. Then all of a sudden a
light bulb flashes 'ding' and it dawns on me; it's not the cable stupid,
it's the rotary switch stupid. And if you had'nt pulled out the cable
stupid, you could have gotten another head and simply re-attached the bowden
cables stupid. Now, stupid, you've gone and yanked the cable from the
plenum, which is damn near impossible to re-attach without major yanking of
other bits.

So now if I want heat, I have to put my hand behind the center console from
the passenger side and move the flap manually. Similarly for cold air during
the summer. Oh well, let this be a lesson to anyone who thinks that the the
bowden cables are screwed up. Check the head first, otherwise you'll end up
feeling pretty stupid like me.

mkb
88 80q