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03 Lancer heater control heater box fix


jwalker1970
03-12-2009, 04:33 PM
I just completed repair on an 03 Lancer. "Heater Temperature Dial Hard to Turn"

Bought the car with a broken off temperature control knob, and a severely binding heater box.

Mitsubishi TSB-04-44-003

requires removal of two pieces in a gear/ teeth kit. Mits part# 7801A110 wholesale cost of kit about $18.00

This kit replaces the two gears that attach to the bottom of the heater case where the temp control cable hooks. It makes the cable turn MUCH Much easier! And you can install it in about 20 minutes from under the dash!

Of course I found this out after I had already completely removed the dash and heater box assembly. (about 4 hours to remove & re-install in the car)

Secondly, for everyone who has a broken dash control knob. There is hope! On every Lancer heater control I found in the salvage yards, the left knob was broken off.

The good news is that the two knob shafts (except the fan switch) will interchange if you carefully take the assembly apart. Be very specific and take some digital pics as you take the panel apart. allignment of the heater knob shafts on the gears, and the gears position in the plastic rack are very specific. (You need to be pretty mechanically inclined, and patient to do this!) It saved me $258 from buying a new heater control.

I went to my local salvage yard, although they said they didn't show a heater panel in stock. I asked to check the car because I only needed a plastic piece off of the heater panel, not a good complete panel. Every Lancer they had in the yard had broken off heater knobs on the left side...... Same as mine. (I didn't tell them that the Right and left knob shafts interchange). My salesman ended up giving me the heater panel for free since I was buying another part.

So, other than wasting 4 hours removing the heater box.... a good lesson. It would have taken me about 20 minutes to replace the 2 gears on the box with the updated ones. And I would guess it took me about an hour to remove the broken heater panel, and replace my broken shaft from another broken panel, and replace it. All of this and a total cost of parts & shipping was under $30.

Good Luck!!

shodawg124
03-31-2009, 07:38 PM
Thanks for the info! My wife's car has the same problem, so it's reassuring to know that it broke because of a defective part, and not because my wife is too strong.

Do you by any chance have a printout of the TSB? I can't find it anywhere online, and the stealership was no help...

RahX
04-04-2009, 01:28 AM
No: TSB-055-003
DATE: December, 2005
MODEL: See below

SUBJECT:
HEATER TEMPERATURE DIAL
HARD TO TURN

This TSB supercedes TSB-04-55-003, issued March, 2004, to add new heater blend door replacement procedures and information, and to update the affected vehicles.

PURPOSE



The heater temperature dial on some affected vehicles may be difficult to turn. This is caused by the heater air blend door link and lever binding, or a dirty and/or damaged blend door gear track preventing the door from moving freely.

To prevent this condition, install a new, improved heater blend door as described in this bulletin.

If a customer complains that the heater temperature dial is difficult to turn:
^ Install the new, improved heater blend door (listed in the PARTS INFORMATION section of this bulletin).

^ For 2002-2003 models only, if the vehicle has NOT already had the heater air blend link and lever replaced as described in TSB-04-55-003, replace the heater air blend link and lever.

On vehicles that do not have a blower motor housing filter already installed as original equipment, install a filter to the top of the blower motor housing, to prevent entry of dirt and debris.

AFFECTED VEHICLES
2002-on Lancer and Lancer Evolution
2003-on Outlander

PROCEDURE
1. Remove the heater case from the vehicle as follows. Refer to Group 55 in the service manual.

a. Discharge and recover the refrigerant.

b. Clamp the heater inlet and outlet hoses near the bulkhead and remove the hoses from the heater core pipes.

c. Disconnect the A/C pipes and remove the expansion valve block.

d. Remove the instrument panel. Refer to Group 52A in the service manual.

e. Remove the heater case assembly.


2. Remove the seal from the case and discard it.


3. Use a flat-blade screwdriver to pry off the clip.


4. Remove the connector.

Do not remove the fin temperature sensors from the evaporator. If a sensor location is changed, compressor failure may result.



Do not remove the fin temperature sensors from the evaporator. If a sensor location is changed, compressor failure may result.
5. Remove the temperature control linkages and gear.

6. Position the heater case on the bench with the control linkage gear side facing down.

7. Open the case. Remove and discard the blend door assembly. Do not remove the mode doors.


8. Install the new blend door (provided in the heater blend door kit listed in the PARTS INFORMATION section of this bulletin). Use the location pins on the door to align it properly.


9. Move the blend door all the way to the left. Then install the gear.


10. 2002-2003 MODELS ONLY

If the vehicle has NOT already had the heater blend link and lever replaced as described in TSB-04-55-003:

Use the heater air blend link and lever kit listed in the PARTS INFORMATION section of this bulletin.

Apply a small amount of grease to the slot in the new door link, and to the gearteeth on the new lever.

Install the new link and lever to the heater box.


11. Adjust the gear so that the raised dot on the gear is aligned with the notch in the blend door as shown.

IMPORTANT :The raised dot on the gear for the door track must be aligned with the notch in the door lever to achieve proper timing. If the link and lever are not installed properly, binding will result.

12. Install the new seal provided in the heater blend door kit.

13. Reassemble the case. Use all of the screws provided in the kit, as there may be one or more broken case tabs. Be sure that there are no gaps after reassembly.

14. Reinstall the heater case and expansion valve block. Reconnect the hoses and pipes. Reinstall the instrument panel.

15. On vehicles that do not have a blower motor housing filter already installed as original equipment, install a blower motor housing filter as follows:

a. Remove the glove box lid.


b. Use a knife to cut a section from the top of the blower motor housing, along the perforated lines as shown.


c. Install the filter with the air flow directional arrow pointing down.

d. Secure the filter with two 5X14 self-tapping screws listed in the PARTS INFORMATION section of this bulletin.

PARTS INFORMATION



Use the Genuine Mitsubishi Parts listed.

WARRANTY INFORMATION



Special Warranty Information: On vehicles that do not have a blower motor housing filter already installed as original equipment, the filter installation described in this TSB should only be done on a customer complaint basis and may be claimed as part of this HVAC system warranty repair. However, future replacements of these installed filters are considered a customer maintenance expense just like any other vehicle filter (oil, air, fuel, etc.).

On vehicles with blower motor housing filters already installed as original equipment, filter replacement is considered a not warrantable customer maintenance item.

theunfrailhale
08-04-2010, 05:29 PM
I'm probably reviving an old thread here but I HAD to say thanks to the previous post-ers for the tips. I was able to easily find the gear assembly and adjust my temp gague. Its summer in vegas and my ac was stuck at a useless temperature. I had consigned myself to spending the 380 to buy the new gague set. (and to think that wouldn't have even fixed the problem!!!)

the tidbit that I will add is, I couldnt find any gagues locally in out parts yards, nor on e-bay, but i found out that the 2003 oultander has the same gague setup and the same problems, so i did a search on e-bay for that and Voila! $60 bucks $75 shipped. Maybe i could have found it cheaper at a parts yard, but the time and sweat I saved was worth it.

so, 02, 03 lancers, 03 outlander. I did a search for "03 outlander heater"... anyways. the majority of this post was to thank the original posters. and thanks to the forum for bein' here.

Dave

KimbrellLD
10-04-2010, 09:41 PM
Read this with great interest, as I have the same issue and now the cable for the temperature selection dial has a bend in it, down near where it connects to the gears.

My problem is that I'm just not understanding where to get the gears needed to fix this issue and maybe you can also let me know if I'm going to need to replace the cable as well.

Thanks for your help.

escamillama
12-09-2010, 11:18 AM
Good stuff, hope this helps out http://members.cox.net/elixirm2u81/tsb/tsb0455003.pdf
I am finding it very difficult to find the knobs and stems. Is anybody else having an air conditioning problem along with this problem?

TO6647
01-06-2011, 01:48 PM
I just found a supplier that sells the replacement switch for $32.23 its called Directmitsubishiparts.com and search for (switch-heater blo) here is the direct link to the page so between them you should be able to find it. Thanks for the info on the gears, I would be upset to replace switch only to break in future because of defective gears. http://www.partswebsite.com/directmitsubishiparts/index.php?i=6&type=parts&action=remove&o=7088618&key=0&optionid=Array&section=&rcatid=&subcatid=&ryear=

tomtom11
04-09-2011, 01:31 AM
I had same problem ... bought gear kit from dealer for something like $25.

Shafts needed for repair broken control panel are available on ebay for around $20.

PMRSTL
10-24-2011, 10:26 AM
I just found a supplier that sells the replacement switch for $32.23 its called Directmitsubishiparts.com and search for (switch-heater blo) here is the direct link to the page so between them you should be able to find it. Thanks for the info on the gears, I would be upset to replace switch only to break in future because of defective gears. http://www.partswebsite.com/directmitsubishiparts/index.php?i=6&type=parts&action=remove&o=7088618&key=0&optionid=Array&section=&rcatid=&subcatid=&ryear=


Please do not order "switch-heater blo". It's the wrong part. That switch is for the blower (middle knob). I made the mistake of ordering it. The correct part is only sold with complete heater unit. I also found this on ebay: http://www.ebay.com/itm/2002-04-LANCER-Heater-Control-Panel-Switch-Knob-Shaft-/250909716581?pt=Motors_Car_Truck_Parts_Accessories&fits=Model%3ALancer&vxp=mtr&hash=item3a6b627065. I bought the actual black knob from Directmitsubishiparts.com.

AZ Roadrunner
11-08-2011, 01:16 PM
Can someone please tell me how to disconnect the heater control cables? Not the ends, but the clamps/clips which hold the cable body. I pinched those black metal clips to no avail. What's the secret please?

jrthomas37
12-14-2011, 01:50 AM
AZ Roadrunner-

My girlfriend is having the same problem.
I went to youtube :)
type in 03 lancer heater control or ;

http://www.youtube.com/watch?v=vcG20LmRZFU

the title is how to fix stuck heater control knob by boosted films.

I ordered the parts from partswebsite.com too, $31.16 with shipping for the parts and I just ordered them 12.13.11 so I will be fixing it soon.

The video shows the guy using a flat head screw driver and pushing from the bottom up.. I haven't attempted it yet, but thought the sooner you get info the better!

Keep in touch
Jake


**the part # for the gears is 7801A110
wire is MR979515

TheKingIsDead
01-18-2012, 10:42 PM
howd that work out for you? was that the right part? if it is im gunna pick it up for myself

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