Air regulator question...

[COACHMEASON]

Well, I call it the air regulator...Its the box with the flap on the inside...My flap is broke and the only thing holding it together is the rubber seal on the flap...Question...Will the flap come out? Is their a fix for the flap while its still inside the box? Ideas?

Thanks
Clint

[Papa Smurf]

This is a bad weak point in the a/c system. I got tired of paying the big bucks for new boxes, or putting in used ones knowing they would eventually do the same thing, so I came up with a way to fix it without taking the whole thing apart. I have repaired several and they work great. Not factory and not perfect, but it works better than the original.

Somebody may have a good fix, if not, I'll try to take some pix and explain mine.

Papa Smurf

[JimKshortstep4x4]

A piece of sheet metal riveted to the door and welded to the shaft has worked pretty well on my diverter box.

Welding is a little tricky but it can be done.

Jim

[LockDoc]

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I am in the process of doing this repair myself. I haven't found any replacement doors, just the whole assembly (for 90 bucks). I was thinking about getting a piece of sheet brass and making a repair piece that could be epoxied to the original door and use the original gasket if it is in decent shape. I haven't been close to a store that has the sheet brass yet. That's the problem with living out in the boonies...

LockDoc

[Papa Smurf]

O.K. Here is a quick and simple repair that works great. Takes about 15 minutes and should last forever.

I start with a Simpson wall tie(because I am a carpenter and happened to have some). Any piece of thin bendable metal about 1" wide and 9" long will work. About 3 1/4 inch from one end bend around a 3/8" bolt to make a radius. Then at 3/4" from the radius, bend it to about 30 degrees.


Now take your diverter and with a dremel, or other suitable tool, cut away some of the plastic housing next to the rubber. Now slip the bent end of the metal through this slot and check to see that it lays close on both sides of the flapper. If it doesn''t lay perfectly flat, don't worry, it'll pull in.


On the long side you'll need to drill one small hole near the end of the metal strip and put a small nut and bolt through the plastic. On the bent end you should be able to put a small bolt through the slots in the plastic and use big enough washers to hold it there. Tighten it all up and you're done. Works great. And saves lots of $$$$$!!!!!



Papa Smurf

[alsohim]

Tks for the pics. I tore it down and the flap was stuck(flap Rod) and now it works perfect. On the back where the cable attaches to the flap there is a switch. What does that push switch control? I think it triggers the a/c compressor but I'm not sure. Again thanks for the tech.

Kaleb