A/C - Temperature Control Unable to Move Positions
87subaru1NUMBER 10-47-87
DATE 3-27-87
APPLICABILITY ALL 1985 AND 1986 MODELS EXCEPT BRAT AND HATCHBACK
SUBJECT: TEMPERATURE CONTROL WORM GEAR ASSEMBLY
If you encounter a customer complaint of a temperature control lever that will not move to the extreme cold or the extreme hot positions, a loose worm gear assembly may be the cause.
Follow these steps for removing and installing a modified temperature control worm gear assembly.
TOOLS NEEDED:
^ A small slotted screwdriver, Example: Snap-on brand, part number SSD204.
^ Number 2 Phillips head screwdriver
^ Number 2 offset Phillips head screwdriver, Example: Snap-on brand screwdriver set, part number ST50.
^ Ratcheting Phillips head screwdriver, Example: Craftsman brand, part number 4116.
FIGURE 1:
MATERIALS NEEDED:
PART NUMBER DESCRIPTION
72011GA210 heater gear kit attachment
assembly consisting of:
*72060GA031 gear (lever assembly)
*72026GA931 gear (plate assembly)
*0431103100 retaining screw
* THESE PARTS MAY BE ORDERED SEPERATELY FROM THE KIT.
FIGURE 2:
PROCEDURE
1. Remove the cover below the steering column.
2. Remove the cable cover on the left side of the heater unit. Remove the control lever cable.
3. Remove screw A and remove the plate gear. See Figure 2.
FIGURE 3:
4. Using a small slotted screwdriver open the clip lock on the heater lever holder. Remove the lever rod and move the rod aside. See Figure 3.
FIGURE 4:
5. Turn the lever gear to the left and locate screw B. Using a ratcheting Phillips screwdriver carefully remove screw B by:
^ Loosening the initial tension of the screw
^ Using fingers to remove the screw. See Figure 4.
NOTE: DO NOT DROP THE SCREW.
FIGURE 5:
6. Remove the lever gear and transfer the lever holder to the new lever gear. See Figure 5.
FIGURE 6:
7. To install the new lever gear, hold screw B in the hole closest to the gear teeth before putting the gear on the flap rod. See Figure 6.
FIGURE 7:
8. Install the new lever gear and start screw B by hand. Tighten the screw with a ratcheting Phillips screwdriver.
9. Turn the new lever gear all the way to the right side and install the lever rod. Close the clip lock on the lever holder.
10. Locate the alignment mark on the new plate gear and using your finger feel the alignment mark on the new lever gear. Install the plate gear making sure the alignment marks are matched. See Figure 7.
11. Install screw A in the plate gear and install the control lever cable.
12. Check the temperature control lever operation by moving the lever to the full hot position, then to the full cold position. If the lever does not reach full cold or full hot, check the heater gear alignment for proper matching.
13. Install the cable cover and the lower cover.
Modified lever and plate worm gears have been used in production since June 6, 1986 starting with the following VIN's.
4 Door 252366
Station Wagon 470962
3 Door Coupe 809197 AND ON
XT 322979
This procedure can be claimed for vehicles within the terms of the Subaru Limited Warranty using:
OPERATION # TIME FAILURE CODE
A711-211 0.7 SGV-29