RED SHARK 1990

Hello members i broke a connection to the flap trying to removed the lever-Can any member post a picture or a sketch where does it connected to. I viewed Dwayne write up but cannot see where the metal part of the flap actuator hook on to. Somesort of plastic connector?

Jascd

Is this what you are looking for? - the centre vent seen side on (89s4)

[IMG]C:\Documents and Settings\jason\Desktop\CIMG3291.jpg[/IMG]

Jascd

Oops, try this

RED SHARK 1990

Thanks Jason i think i broke the tab that holds the lever... now how do i replace one . Any pict without the metal arm attached to it? Any other members that have a pict after the arm removed?

dr bob

Th efour little fingers that you see poking through the hole in the arm are molded as part of said arm. If you break off more than 1 of them, the arm won't stay attached. An option I see is to remove the flap assembly (not clear right now on what's involved for that), cut the remaining tabs off, drill and fit a threaded insert into the arm, probably with glue. Then a small screw through the actuator into that insert in the arm. Needs to be done pretty carefully, else it will either bind or rattle.

For where we live, you can probably get by with somehow holding the flap retracted all the time. It's primary purpose is to partially restric center vent flow so that footwell/heater and defroster vent flow is improved.

Jascd

yeah, I think its tricky to fix, and that's why mine is still not fixed...

There is a fix to drill a hole next to the actuator from the front and then do a bit of keyhole surgery then patch the hole. Still sounds fiddly, but next time I have the centre console out I'll try it because despite how it looks in that photo, my actuator arm does not seem to be connected to the flap. Somehow its come adrift and retained that plastic pin and maybe a bit of the flap.

RED SHARK 1990

Thanks, Jason i think i broke the black plastic arm ? The actuator metal arm does not seem to reach it,the space is like an inch short????

dr bob

I have the non-airbag car so there is visibility for that lever through the airbox port for the glovebox cooling hose after the glovebox is out. I don't know what access you have on the airbag car.

I was able to manipulate the flap from the top to get the plastic lever to move to where I could get the end of the metal actuator arm to sit on those four little fingers. Using a small socket on an extension to push from the side, I was able to roll the metal arm from the diaphragm end as I applied light pressure with the socket through that hose port/nozzle to engage the arm as I rolled it. In just a couple tries it rolled right onto the fingers and all was well.

Others have used a small hole saw to cut an access directly into the front of the airbox, Doing that, you can reach in with a finger and engage the arm onto the little protruding fingers. Before you drill, stop by local Home Depot and get a rubber plug to use there when you are done. Then select the holesaw that matches the plug. It's no fun trying to adjust the size of the hole later; you really only get one chance with the holesaw. I've seen this done with a piece of duct tape sealing the hole too. Hole needs to be big enough for your finger to get through easily.

HTH!

RED SHARK 1990

Hello DR.BOB well from the pict from Jason i think i broke the black piece of plastic which has a male clip on it-the only thing that i see in the 1 inch hole is the two white color nibs . The arm does not reach anything at least another haft inch. Does any member have a pict of one intact and the lever from actuator connected to??????? Or a drawing since i am clueless for a week now....Thanks

Rob Edwards

I stopped by 928Intl today and shot some pics of an airbox, I'd never seen one out of its native habitat.

First, some general pics:

Front:



Top/Pass Side:



Bottom:



Driver's side:



Engine Compartment side:




Regarding the comb flap, here's a view of the comb flap lever as viewed thru the defroster vents on top of the box:



Same thing, viewed from the passenger side duct, as shown by Jason in post #2. This is the position with no vacuum applied to the actuator:



Shot of the comb flap position with no vacuum applied to the actuator:


And position with 'vacuum' applied:


Side view with 'vacuum' applied



Oh, and here's the hole I made on my airbox to be able to push the actuator arm onto the comb flap lever. I'm holding the actuator arm in its orientation in situ.

RED SHARK 1990

Thanks ROB that is great! Now at least i have an idea what to do...Thanks for the great picts- i will see you soon.

axis of evil

What year model do the pic's relate too? I'm about to remove heater/aircon from a 1982MY,and I am anticipating the usual "oops" type problems when removing/reassembling, are the1982's similar/same as pic's?

Rob Edwards

Honestly I have no idea what year that airbox is out of. I know that the early boxes had a six-solenoid strip on them, and the one pictured has five. Not sure when the conversion to five occurred.

BC

I have one in the 78 Luan that you can come and look at - there is no dash so you can see how it all is together.

rluvsporsche

What's does the center flap do? I'm having trouble with system as well. When the units on the off position hot or cold air goes through the center and door vents. I also get some hot air when A/C running. Any help would be appreciated.