Repeat

Are the repair kits any good and is it an easy or difficult job? What is the chance of success in rebuilding one? Pelican parts has a new one which appears to be the center vent element for $47
https://www.pelicanparts.com/More_Info/1168001175INT.htm?pn=116-800-11-75-INT&bt=Y&fs=0&SVSVSI=3306

Can't tell from the pic whether the legs are threaded or not.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

The repair kits consist of new rubber diaphragms used inside the vacuum pod. The pods snap together and using a small flat blade screwdriver can be snapped apart. George sells quality parts and I believe the repair kit is about 1/3 the cost of a new vacuum pod. The legs are not threaded. I have broken several of the legs off while trying to push on the factory retaining clips, hence the reason I decided to put threads on the legs and use nuts to retain the pod to the metal brackets.

I went in with a borescope and snapped this pic. I think I should be able to make a long reach pry tool to take those 2 push on retainer rings off and remove the element. If so, I will think about rebuilding it and cut threads on the 2 legs and re-install.

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__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I made a pry tool, plenty sharp and plenty strong but the clips just won't budge with reasonable force. I did not want to pry too hard fearing I may break the plastic legs. A closer look at the element by the blower motor shows those round metal retainer clips are meant to go on one way and not come out. It looks like the harder you pry, the deeper those leaves will dig into the plastic.

If I can split them with a hammer and a sharp chisel, I think it should then pry off. But there's a chance I will break those legs hammering on them.

What's the trick?

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

The only way I've been able to remove them is to use a stainless steel pick. Work the the pint of the pick under one of the bent ears/wings and pry it. You need to bend at least two of the ears to get movement. I then use a pair of long thin diagonal cutters to snip the ring.

It is truly a study in patience and by the time you are done the removal of the dash doesn't seem as daunting.

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“Whatever story you're telling, it will be more interesting if, at the end you add, "and then everything burst into flames.”
― Brian P. Cleary, You Oughta Know By Now

How about a Dremel with cut-off wheel to split the metal washer?

In this thread W123. My experience with replacing all AC vacuum elements without removing the dash. Dave Morrison break the legs off: "It makes it easy to remove the lock washer by inserting a flat screwdriver under the metal lock washer, into the rubber washer and twisting the rod off the element."

I have given up on the idea of rebuilding the center element with the dash in place.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I have successfully removed the clips by cutting then off with a pair of diagonal cutters.

Please clarify if this was done with or without removing the dash first. There is a huge difference.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

With dash removed.

You can probably cut off all three legs of the vacuum pod with a pair of diagonal pliers by reaching through the glove box opening. You will then need to buy a new vacuum pod.

Thank you!

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Have you tried that? I don't think there is enough clearance with the correct angles with the dash in place to maneuver a diagonal cutter.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I have been able cut off the legs through the glove box opening with a small pair of diagonal cutters. My offer still stands. If you send me your email address I am glad to send you a set of written instructions for the removal and installation of a W123 dash. The job does take some time but is not complicated and can be done with simple hand tools.

With the flap propped open, my center vents are working, everything is back together, I am not pulling the dash!

Took this pic of the foam tube while it was open. Appears to be in good shape.

Attached Thumbnails

 

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked