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108/109 Heater Control Replacement

As you probably know the 108/109 came with some pretty flimsy heater controls, many of which are broken or on the verge of breaking. Here is a great tip on how to replace yours.

You will need a good source of light, a 10 mm socket, a needle nose pliers, short phillips and slotted head screwdrivers and a small mirror is very helpful. A mirror on a stick works great. Most of the prep items are self-explanatory but I will detail the procedures for anyone not familiar. You may want to draw a diagram showing which cables go where as some levers have multiple cables on them. The whole process should take about an hour or two. Do not forget to make sure all control cables move freely and easily before installing new levers. Pay special attention to the water valve levers. They should be oiled and worked back and forth with cables removed to insure ease of movement. They're located directly behind the ashtray opening and can be reached easily after you've removed the glove box as detailed below.

The items to remove first to creating working room are:

Glove box: remove lock catch, light and plastic retaining plugs, (on some you pull the center section out on each plug and on other styles push the center down and completely out of the retaining plug). Then pull the plugs out and remove the box insert.

Cigarette lighter assembly: unplug and unscrew the nut from the back of the unit.

Ashtray frame: remove the three screws from just inside the housing and also the glove box light button switch, (it's held by a plastic nut on the outside).

Dash top speaker: remove securing screws.

Radio: this comes out quite simply if it's a Becker but it will be a project in itself on aftermarket units.

For Becker units: Gently pull chrome trim plate off. Remove the set screws from the volume and frequency knobs. Remove plastic face. Remove the clamping bolts and pull radio out disconnecting the wires if they're too short to leave attached.

Heat controls: Remove the two 10 mm nuts from directly behind the ends of the chrome faceplate and pull the plate away from the dashboard. Unplug the two electrical connections to the unit, (fan switch and lighter/ashtray lights). Next remove all the cables. Simple clips retain most of the cables. Screw retainers hold two of the temp cables, (there are holes in the top of the metal assembly to reach the phillips head fittings that must be held tight to remove the slotted cable screws from them). Move the levers to the appropriate position to access the holes for the phillips head fittings.

Remove the complete unit out of the glove box opening.

The individual disks can be removed from the assembly by removing the black plastic caps from the top and bottom of the assembly.

Installation is the reverse of removal.

Once again, don't forget to make sure all cables move freely before installing a new unit or levers.

Note: Burned out bulbs can be replaced by removing the large black plastic caps on the top of each disk set, (they're held in place by phillips screws). Then lift the bulb carrier out of the disk assembly.


This tip was added to our database on Thursday, January 29, 2004.

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