reconnecting control cables to heater levers

[chicagopagoda]

I was able to replace my cracked levers but am having a heck of a time re-installing the cables. Following the advice from the tech manual, I lubricated the bale housings and they slide well now. The problem I am experiencing is that when I slide the cable into the lever pins and tighten down the slotted bolt one of two things happen...sometimes both: the end of the cable bends into a "C" or "U" shape and/or the cable pops out of the lever pin hole. I get the feeling I'm doing something wrong but dont know what. By the way, the upper (blue and smoke) levers didnt seem to have this issue as much, but both lower (red) ones are both problematic.

[66andBlue]

The wire needs to be placed between two special conical washers to prevent slipping and/or bending.
Don't place the wire against the nut.
They also must be oriented in the correct way to work. Perhaps the picture will help.

[bpossel]

Fred,

Look at Alfreds pictures.  The cables must be straight (including the ends) for them to work properly.  When I first bought my car, a couple of the cables had a "kink" and one had been bent into a "u" shape and fit around the lock nut.  Periodically, these cables would come loose and never really worked correctly.

The cables must be straight and one end will slide into the hole on the pin and is held in place with the lock washer and nut (as seen in Alfreds pic).

You may need some new cables?

Good Luck!
Bob  

[chicagopagoda]

Thanks guys. This is exactly what was missing from the equation. These washers werent on the unit when I took the cables off.

[Dave Gallon]

The conical washer is 108 990 00 41, MB USA list $3.90, my price $2.83. I believe the flat washer is a standard DIN 4mm washer. It sounds like you need new control cables, also. They are 113 833 02 31, MB USA list $6.25, my price $4.55. It is also a good idea to lubricate the new cables as they are inserted into their spiral sheath.

[ja17]

Hello Fred,

Are you aware that some of the lower cables are secured by tightening the hidden phillips screws through the speaker opening?