As many of you have experienced, the air & heater control levers can be hard to adjust after may years of neglected service. Our Technical Manual has a very good description on how to disassemble and lube the air & heater control system. So did I. When I disassembled the control unit, the aluminium frame holding the levers cracked apart. Obviously, the frame had become vulnerable after many years (see first picture). I tired to put it together with epoxy, but it didn't last when mounting back in the car. My only chance to solve the disaster was to find a new(er) frame. I checked with the well known vendors of W113 parts but none of them sold the frame separately, only complete units with levers. My levers are in good condition and not needed to be exchanged so I turned to eBay instead. Luckily, i won a complete unit with cracked levers but the frame in good condition, at a reasonable cost. I switched over my controls on the new frame and mounted it perfectly in the car.
Lubing the control wires made everything moving easily, except the air distributor flap, which still was stuck. So I removed the air distributor box and found that the flap was stuck in the corners. Maybe the plastics has expanded somewhat since new. The mitigation was to grind off the corners and edges of the flap with a fine rasp. Eventually, the flap moved freely. Finally, this maintenance project was done
