David, there could be a number of problems there. You need to diagnose things separately... check all the vacuum pods with a MityVac as described in the first few posts of this thread, and then use the factory climate control service manual to test each of the various sensors in the system (click here). It could be a flaky pushbutton unit, but it would be a shame to spend $$$ for a rebuilt unit and find out that's not the problem (BT, DT).

:stuart:

Just tackled the pod replacement project this weekend. It took the full 5+ hours GSXR estimated (would have been faster if I didn't waste half an hour trying to find the clips I dropped behind the radio). Thanks GSXR for your tips and kudos to Fastlane for getting me all the right parts the first time (given the help I got here I'm happy to pay a bit extra an support this site). All my old pods were actually good (yes I replaced them anyway) except for the diverter which was bad enough to throw the whole system off. I guess one bad Pod can bleed enough vacuum off to make all the others ineffective. Anyway I'm glad to have it done and for those who haven't done it it's worth the effort.

LRG, what would you estimate the time for just a dash top R&R to be?

Thanks,
Sixto
87 300D

I'd guess you could R&R the dash in about 4 hours, maybe less. You'll need to remove the glovebox, steering wheel, instrument panel, pushbutton unit, front speakers and both kick panels before you can pull the dash. It helps if you've pulled some of that stuff before. All in all it's not especially hard, it's just a lot to do.

You don't need to remove the steering wheel. It will telescope out of the way.

I agree but for me working around it adds about as much time as just taking the dang thing off.

Correct - I prefer to remove it, since it only takes about 5-10 minutes total. Just be REALLY careful not to break the cruise control stalk with the wheel removed! Models without a telescoping wheel may not have the choice to leave the wheel in place, I'm not sure, never tried that with the "fixed" column...

:1eye:

Does the steering wheel have to be out of the way for more than removing the gauge cluster?

Sixto
87 300D

Not really, it's just a whole lot easier to remove the kick panel and pull the dash out without the wheel getting in the way. Bio's right that the wheel doesn't HAVE to come out to remove the dash. I just thought it was easier and I also have the later leather steering wheel that I didn't want to nick up as I removed the dash.

I'm planning on replacing all the pods on my 86' W124, however, it seems as if the footwell flaps are nonexistent ANYWHERE? **********, partsexpress, KO, etc.
I'm looking for part # 124-800-01-75 maybe I'm not searching correctly but it seems as if no one carries them anymore :(? I'm welcome to links if anyone can find them :). Great article btw, I've been following this subject for years and I think soon I'll be able to scrap up the money to overhaul all the pods...and perhaps this will motivate me to get the AC working :rolleyes:

Click "Buy Parts" link at the top of the page. I bought that exact part number 124 800 01 75 (invoice in front of me now) last August. Whether they still have it is another question.

Looks like they are special order now from both parts places.

Yep, may be special order (comes from Mercedes), but they should definitely still be available. Hope you're sitting down for the price though, list is $54 each, $43.50 wholesale... and there's two of 'em for the 1986 & early '87 models!

:zorro:

Thanks guys! These things really are expensive....and it seems as if the price has gone up in the realm of $10. And I thought the Bilstien HD's were expensive :P

I'll have to e-mail rusty when my bank account starts looking healthy again. I'll be sure to add pictures when the job is done for the forums sake.

Does the console have to come off to get at the footwell pods? One of mine is bad and I'm replacing all of the pods anyway. I can't quite figure out how to get at the footwell pods, even with the radio, ashtray, PBU, etc. out of the way.

Remember that my old 300D (W124, OM603) has a build date of July 1986 so it has two round footwell pods, not the single rectangular one of the later models.

[Edit]

It was clear that removing the footwell pods, which are not the twist-lock kind but are held on with the three pins, was gonna be a real b*tch, the left one worse thyan the right due to cables. Fortunately, only the right pod was bad. After trying half-heartedly to remove the pod, I eventually realized that I could take it apart without removing it, substitute the diaphragm from my replacement pod, and button it back up. That took about ten minutes and was the last pod in the job.

Tomorrow I'll post some learnings and tips that may help someone else in the future. As always, thanks to those who came before, allowing me to shamelessly copy them.

Jeremy