Good to hear you have it sorted out.

The 1986-87 USA model years have a different control panel / pushbutton unit vs 1988-up due to a change in the sensor/switch used for the AC compressor safety shutoff. 86-87 models use a 3-pin temperature switch that triggers at certain coolant temperatures, to turn off the AC compressor if the engine gets too hot. This varies by engine. 1988-up changed to a 2-pin sensor which tells the control panel the exact engine temp, and the control panel then decides what to do with the AC compressor. The 1988-up control panel should work in a 1986-87 vehicle, but the high-temp safety function would be disabled as the 88-up panel won't have a temperature signal available.

BTW, the system functional description is available in the owner's manual and the factory manual, climate control section. This explains how each mode works, what temp air comes out in various settings, etc. EC = Economy which simply means "AC compressor off".

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95 E300D, Planning on tackling a few more pre failure items on my car, including replacing/rebuilding the vacuum pods.

I've read through this thread a couple of times and really appreciate the comments.

I have a few questions.

Does anyone know of instructions or videos that specifically are for a 94 or 95 E300D?

I'm planning to go to Plano TX soon to check on parts availability. Since the short rubber connectors are low in price is it best to replace them?

With the dash off and the instrument panel out, what are some other suggested PM things that could be done. I think I've read that the solder points on the back of the instrument panel should be reheated.

Since silicone is touted to provide a very long lasting protective coating to rubber, what's your thoughts on coating the new diaphragms with silicone oil or a light coating of silicone grease? It seems it would reduce friction a bit also.

Does any of the 'water proofing sprays' seal possible small vacuum leaks? I'm thinking of trying one of the old time sprays that spray a waxy coating for electrical connections.

I'd especially like to thank the one's that have taken the time to create videos, websites, how to's, etc. I'm watching a youtube one now titled:

W124 dash removal and automatic climate control vacuum actuator pod replacement

Video is easy to folow so far and expect it to help with my dash removal.

Most of the instructions for earlier cars also apply to the 94-95 E300 diesel. One difference may be that your car has a passenger airbag, early cars do not. The bracket are different vs the glovebox.

The rubber connectors are cheap and it would not hurt to replace them, especially the ones inaccessible with the dash in place.

If you treat the rubber diaphragms, make sure it is a product SPECIFICALLY designed for rubber. Otherwise, don't apply anything at all. There's usually no issue with leaks if the pods are good and vac fittings are tight.

Plan on 10-12 hours working slowly if you've never done this before. Next time around will be half that, if you ever do it again.

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The part #'s for my 95 E300D W124 I believe are:

124 800 29 75 left side recirculate/fresh air flap
haven't found one yet

124 800 30 75 riight side r/f air flap
On order from Park Place Mercedes

124 800 03 75 diverter flap
On order from Park Place Mercedes

124 800 02 75 center vent flap
found on Pelican parts

124 800 26 75 defroster pod
found at ******** cheaper than P parts
a u t o h a u s
124 800 09 75 lower footwell
so far only found used

201-805-01-03 Connect vacuum Tube to pod I believe hese are short right
angle ones,
One parts website diagram shows there are (9) of these
used for vac
pods 500E site say's 10-12 of them

201 805 01 22 'Y' connector 500E site says 3 of these I'll try to order these

The following 500E tutorial has pictures and good commentary:
5 0 0 E b o a r d
https://www.*********.co/forums/threads/how-to-replacing-w124-climate-control-vacuum-pods.1349/

I've failed to locate two vacuum pods.

Does anyone know if Performance Analysis kits will fit the 94/95 part number

124 800 29 75

right side fresh air flap vac pod? Also can the innards of part #
124 800 30 75 left side be taken out and work in my
old part 124 800 29 75?

The other pod is the rectangular lower footwell pod
124 800 09 75 that I haven't been able to locate. Fits 87-95

When I tried calling Performance Analysis this morning, 5/4/2021, the auto answer message said they were temporarily closed while the owner George Murphy is recovering from heart surgery. Hopefully the recovery will be quick and goes well.

The PA kits do not work properly with the dual-chamber pods, travel is limited and the flaps will not fully close. Click here for a recent post with more details.

Yes, the internals of #30 can be used to repair #29.

I would be surprised if Pelican can supply center pod #02, which has been NLA for years. The PA diaphragm (ACD 2010) will repair this pod correctly. If Pelican had one left, it was probably the last one anywhere. It's showing NLA on their site now (link).

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thanks for the link explaining the problem with the 2020 kit.

I checked my order confirmation email from Pelican Parts for the 124 800 02 75 center vent, it does show it is on order and will ship 05/10 about. I won't be surprised if I get a NLA email soon.

I'll order a 2010 kit for that pod from Performance Analysis when they're taking orders again.

It's confusing trying to tie part #'s to positions and repair kits.

Does the 2010 kit work for any of the other pods?

Which pods innards are interchangeable?

The 2010 kits fully repair the center vent (#02) pod, if the housing is intact.

The dual-chamber pods have 2 diaphragms, and the 2010 kit will repair/replace ONE diaphragm only, the outer one. In my experience, almost all of the dual-chamber pod failures had this outer diaphragm failed, so the 2010 kits would fix those pods. However, some people have found both diaphragms failed, in which case the entire pod (or, complete internals) need replacement.

Internal components should be interchangeable if the pod size/diameters are identical. I believe all the dual-diaphragm pods are the same size, at least on the 124. Remember the rectangular/oval footwell pod almost never fails, and is accessible without pulling the dash, so you can skip that and maybe source a good used one in case it ever fails in the future. I've never seen, or even heard of, a late footwell pod failing.

GSXR, That's really good information.

If the Mercedes was a musical instrument, you'd probably be in the Berlin Philharmonic.

I'm digging up this awesome thread from the past! I'm going to replace all pods while the dash is out, and would like to know am I able to purchase all but one of these items from multiple sources? My VIN is B142216 and it's a 1990 300E base model. FCP Euro has one pod, ********AZ also has one, not sure who else I should be looking at.

Also sounds like pods can be rebuilt from known good or new pods so it stands to reason i may be able to rebuild the center vent pod 124-800-02-75 since it's NLA. Looks like Pelican parts is down for maint currently.

Thank you.

Copy/paste from eariler.

124-800-00-75 - Defroster flap control
124-800-02-75 - Center vent air flap control
124-800-03-75 - Cold air flap control (diverter)
124-800-04-75 - Main air flap control (Left)
124-800-11-75 - Main air flap control (Right)

124-800-01-75 - Footwell flap control (Round, 2 required) - Up to VIN 289309
OR
124-800-09-75 - Footwell flap control (Rectangle, 1 required) - From VIN 289310

__________________
1990 300E
124.030
chassis 103.983

Wish I could go back and edit post #115 (and others)... the defrost pod has a VIN break circa 1990, and the main flap pods are different for cars with dust filter (all facelift, 94-95).

The footwell flaps control VIN break is A289309 / A289310 which is circa 1986. Your 1990 car at B142216 uses the "rectangle" pod which almost never, ever fails. Leave this alone until it does fail. It's NLA anyway.

You will most likely not be able to buy all the other pods from a single vendor, as almost all of them are NLA now. The diverter is a different size than the others and is not rebuildable. Pelican claims to have 2 left in stock, maybe.

The center vent can have the diaphragm replaced with the Performance Analysis ACD-2010 kit (link).

For the remaining 3 pink, dual-chamber pods it's the "small lift" diaphragm that usually fails, and the ACD-2010 kit is an economical way to repair those pods. Just don't use the -2020 kit. If the "large lift" has failed, you'll need to obtain a good used one.

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Thank you for taking the time to reply, it clears things up a ton. I'm glad I posted up my VIN for clarity. My 1990 has no dust filter, which I presume to be the "cabin filter" that's accessible from the windshield cowl, after opening up the hood straight up. Is this the correct assumption?

I won't order the footwell flaps then per your comment. It's easily accessible with the dash in place. Easily is being generous I'm sure.

I'll order:
124-800-00-75 - Defroster flap control [Up to VIN B258236]
124-800-04-75 - Main air flap control (Left) [Without dust filter]
124-800-11-75 - Main air flap control (Right) [Without dust filter]

For the center flap, i'll get Performance Analysis ACD-2010 kit. It sounds like this ACD-2010 kit can repair multiple pods. How many kits should I order?

Pelican has the following item, should I order them?

The part number below doesn't match any of the numbers on my list.
A/C vacuum actuator - Right 124-800-30-75 $66 link

I don't know what INT means but the rest of the p/n matches.
A/C Vacuum Actuator 124-800-00-75-INT $81.25
link

So, it looks like I can only order the defrost POD from Pelican.

__________________
1990 300E
124.030
chassis 103.983

Sorry for the late reply, the forum notification went into my spam folder.

You are correct - the dust filter / cabin filter is only found on "facelift" models, 1994-95 USA model year.



Depends if you plan to rebuild a dual-chamber pod by only replacing the small-lift portion, assuming the large-lift portion is still good. There are 4 total per car (1 center, 2 main/recirc, and 1 defrost). Hopefully the 2010 kit is still available - if you buy any, please post the current pricing. I think they've gone up in recent years.



If you try to add either of those to your cart, it then shows "Out of stock". Pelican apparently does a bad job of managing their online catalog / inventory.

The -INT suffix is just a Pelican thing indicating a supplier or brand. The #30 part number is the same basic dual-chamber vacuum actuator as used for all main air / recirc flaps or defrost, but with a different metal rod attached. Pro tip: If you can find any new/NOS dual-chamber pod for 124, the metal rods are interchangeable. You may need to disassemble and re-clock the pod to get the vac hose nipples pointing in the right direction relative to the mounting ears, but that's doable.

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this info was in an email that I got from George Murphy who sells the rebuild kits:

copy/paste:
Our kit provides repair diaphragms for the vacuum actuators - no need to buy new pods unless you want to and can find them (Mostly NLA anymore).

G. Murphy



124 HVAC Part number list:
======================================================
#38 - 124-800-00-75 or 124-800-26-75 - Defroster nozzle flap control (dual chamber) – use ACC-Di 2010 & 2020 to repair
#39 early (up to VIN A289309) – uses two 124-800-01-75 for foot well pod (two small round units, 1986 to early 1987, two required). May use 124-800-03-75
#39 late (from VIN A289310) - 124-800-09-75 (NLA) - Foot well pod (white oval unit), (late 87 through 95), use 126 800 1475 – adapt as necessary
#40 - 124-800-02-75 - Control of shutoff flaps (single chamber, bayonet mount) – use internals from 124 800 0375 to repair or a #2010 diaphragm – which ever fits.
#41 - 124-800-03-75 = Diverter air flap pod (single chamber, attaches w/3 clips) – (Easy method - open a new 124-800-03-75 (supplied) and move the internal diaphragm to the installed 03-75).
#42 - 124-800-04-75 or 29-75 - Main air flap control - left (dual chamber) - use ACC-Di 2010 & 2020 to repair
#42 - 124-800-11-75 or 30-75 - Main air flap control - right (dual chamber) - use ACC-Di 2010 & 2020 to repair
 
Our W124 HVAC repair kit includes the following: (Be sure to send VIN)
To repair dual diaphragm actuators #38, #40 and #42 (x2):
• 4 each #2010 diaphragm $10.50 each x 4 = $42.00
• 3 each #2020 diaphragm $10.50 each x 3 = $31.50
To repair actuator #41: 1 each # 124 800 03 75 actuator $35
To replace actuator #39: 1 each #126 800 14 75 oval actuator = $35 (modify as needed)
Plus Shipping & handling (Usually $12.95 USA Zip codes)


See https://www.youtube.com/watch?v=0SU6CFb0W7s for vacuum actuator R&R.


Many good photos at: Index of /images/W124_dash



Part numbers for the E500 (and late 124 chassis 94-95):
124 800 29 75 -- recirc/fresh air flap pod, left side (Repair with ACC-Di)
124 800 30 75 -- recirc/fresh air flap pod, right side (Repair with ACC-Di)
124 800 03 75 -- diverter flap pod (Use internals from new 03-75)
124 800 02 75 -- center vent flap pod (inside the evaporator box) (Repair with ACC-Di)
124 800 26 75 -- defroster pod (Repair with ACC-Di)
124 800 09 75 -- lower footwell pod [rectangular] (NLA) Use 126-800-14-75
Some 1993 and older cars (without factory dust filter) use different part numbers for the recirc/fresh air & defrost pods. Be sure to note vacuum port direction when re-assembling.

Attached Thumbnails

 

__________________
1990 300E
124.030
chassis 103.983