Broke the clip that lets the vacuum pod move the fresh air flap. Is this fixable without pulling heater box? Anyone know the part number?

Fixed by reusing the bushing/clip, I only broke the retaining bits. Used some zip ties, very strong adhesive tape, and cable tie mounting plates to make sure the rod is always pulled into the bushing. Hard to explain, but it will work for a while, or until I get my 3d printer

Hello. How do you access that fresh air flap. I think I have an issue with it being stuck open and a lack of heat and a cold air leak in the winter. I have an 85 300td wagon. Would it be in the same location as yours?
Thank You.

Before you mess with the flap & pod, I'd suggest performing a vacuum test on the change-over valve (Part #: 000-800-04-78-M22). The valve is located behind the control switches for your antenna, sunroof, defroster, etc. It should be number 5. If you hook up a vacuum pump to the output side of the number 5 valve, with the engine running, you should be able to detect a vacuum when the valve has 12v applied (you can also hear the solenoid in the valve move when you apply 12v. Next check to see that your valve holds vacuum. Use your vacuum pump (buy one, trust me, it will pay for itself very quickly) to pull vacuum on the line you just disconnected - if it holds vacuum and the flap moves, your pod should be fine.

If your valve doesn't work when supplied with 12v, replace that. If your valve is never supplied 12v, your problem is likely electronic - somewhere in the switching unit probably. If your pod doesn't hold vacuum, it needs to be replaced or rebuilt.

The flap & pod are located on the far right side of your dash, vaguely underneath the speaker. To access it, you can either remove the dash pad (and get great access, but it's a lot of work - worth doing if you plan on replacing all 5 pods IMO), or you can access it with the dash in place.

To access it with the dash in place, remove your glovebox liner, the glovebox door (optional, but will be less frustrating if it's out of the way), disconnect the corrugated hose to the right hand vent and push it out of the way, and remove that vent. You'll still need fairly small hands to work in there.

To pull the pod, you need to disconnect it's vacuum hose, the lever that operates the flap - push it away from you to disengage it from the flap, and remove the pod itself. Removing the pod requires depressing a tab that keeps it from rotating, and rotating the body out. The tab is located on the far side of the pod, basically you can't really see it, but you should be able to feel it and push it in.

If you decide to rebuild the pod, you might look up George Murphy on this site, he has some parts you might find interesting. One important note is to use a sharpie to mark a straight line from the linkage to both halves of the pod. This will let you realign everything before you reassemble it.

"Assembly is the reverse of removal"

Extra info: http://www.peachparts.com/Wikka/W123HVACVacuumActuators and http://www.peachparts.com/Wikka/W123Evaporator - you really don't need to remove the whole evaporator, but these will help with anything I might have forgotten.

Great info...Thanks so much for the help. Well written.
Is it possible that this row of valves you speak of is on the side of the console near the passengers left foot area under that carpeted panel just below the console/under dash transition? I have an 1985 wagon and I thought I saw something like the part number you listed, but there was a line of 7 or 8 of these valves with colorful stickers on them at one time, when I had the console out?

Or.... is this a single valve behind those antenna switches labelled number 5?
Thanks again.

Huh. Honestly i dont know on a wagon. On my 85 sedan it was a row of valves labeled 1-5 under the center switches. Try following the hose from the pod and see where it leads you