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  #1  
Old 12-28-2011, 07:33 PM
zeke's Avatar
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Location: The Alamo City, TEXAS
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manual heater bypass valve

Is there a trick to getting the cables off of the little plastic arms and then back on the replacement unit?

I made a bit of a mess of the cable on the donor at PnP getting the valve off and don't want to repeat that mistake on my car.

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Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

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2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #2  
Old 12-29-2011, 10:38 AM
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What you need to do is squeeze the coil of wire on the lever with pliers to give it some back torque, allowing it to expand enough so you can remove it.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #3  
Old 12-29-2011, 05:57 PM
zeke's Avatar
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I tried that on the PnP car, but there is a flare at the end of the peg that the wire coils on that I couldn't seem to get over.

Someone recommended cutting the plastic peg on the trashed valve, which would work, just still not sure how to get it on the replacement.
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #4  
Old 12-29-2011, 06:28 PM
Stevo's Avatar
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Join Date: Apr 2002
Location: NW WA
Posts: 6,299
Its been a while but I think I got enough back torque to slip it over that raised part because I replaced that valve on my 79 240. Dont remember just what type of "squeezers" I used.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #5  
Old 12-29-2011, 07:20 PM
zeke's Avatar
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Join Date: Sep 2007
Location: The Alamo City, TEXAS
Posts: 1,189
ok, That did it...kind of a squeeze with a little wrist flick and it came off pretty easily. Snapped right back onto the replacement peg.


Thanks again Steve!

__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT

Last edited by zeke; 12-29-2011 at 11:05 PM.
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