In the manual this is pod number 40. Right behind the acc controller and real PITA to get to. I red the first page and thought okay no big deal. Remove 4.5 mm screws and away we go until I turned the page and found it showing that you disconnect the control rod from the top of the unit without the dash in place.

Is there any way to disconnect the rod on this pod without having to pull the dash to get at it?

I found that this pod has a tear in the diaphragm and need to repair it.

Just on a side note, has onyone tried repairing one with a product like Shoo Goo or Barge cement?

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'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique

I've tried the cement route and it won't hold.

I also have removed the pod behind the pushbutton controller without removing the dash.

It's a tight fit. You will have to remove the radio and bushbutton controller of course, along with the switches. There is probably a plastic thingy covering the rod extending out of the pod. This must be removed first. Then pop off the arm at the joint (that sounds like it hurts). Remove the vacuum line and then twist the pod to remove it. There is a tab that must be pressed in to make the pod rotate. It will shear off, but it will take a lot to do it. I've done it on other pods before.

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

I was just checking out this web site and thought it might be of help in repairing the pod once you get it out. I think I might be doing the same thing soon.
www.autoluxmbz.com

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1983 300SD
200000miles

If I cna ever get the darn thing out that will be handy.

I am trying to see how int he world if I do get to the clip holding the rod and get it released (not likely) then my bigger wquestion is then how in the world to ever get it back together. I'm pretty close now to removing the console and see if that gives me better acces. i hate to go this far and then leave the stupid thing disconnected but that might be the other option as it still blows on AC just not on cool air on the economy switch.

I assume this is due to the high volume of air beign forced through on the AC setting such that it forces this flap open to soem extent allowing in the cooled air.

I can do most anything on these cars but I HATE this part of it when you cannot get to a small part due to the installation methods used.

__________________
'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique

The repair of the vacuum element, by replacing the diaphram, is only done for the 80 and prior models. After 1980 ( don't hold me to that date, may be 79) you just replace the unit with a new one. They are not that expensive and do you really want to "glue" it and have to go back in the dash again in a couple of weeks/months??????

http://catalog.eautopartscatalog.com/mercedesshop/sophio/quote.jsp?clientid=catalog.mercedesshop&cookieid=1I8107Q051I8107UPU&baseurl=http://catalog.peachparts.com/&partner=mercedesshop&year=1983&product=O4010-70075&application=000377396

Dave

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1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

I got replacement diaphrams from www.autoluxmbz.com and they are the exact replacement for the original on my '84SD.

I know what you mean about that center pod being a bear. I used stainless steel safety wire (a light but strong wire) and a rod (possibly an old screwdriver) with a hole drilled in it large enough to feed two strands of the wire through. Cut about a 12-18" length of the wire, loop it around the pod and insert the ends through the hole. Pull the wire back along the rod and then twist the rod to snug the wire around the pod to the point where it will release the clips.

Of course, it always helps to hold your mouth just right.

__________________
Sam

84 300SD 350K+ miles ( Blue Belle )

but these appear to only be repairable by pulling the whole pod out. Tell me this is true...

I'm beginning to think of leaving this until I have a need to pull the dash.

I hate to give up more than I hate working on this part of the car but I see no reason to dive into the entire dash for this pod since it does blow air out the vents when the ac is on even with the pod plugged off from the vacuum system. I just thought it would be nice to have everything working as it should...

I'll give it one more shot tomorrow and then put it all back together if I can't get any further on it.

if someone could confirm that in fact you cannot fix it with only the back half off that would help in my decision making processes such as they are...

__________________
'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique

That is where I got my replacement diaphrams from.

__________________
Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

I have removed every pod (except the one above the drivers knee) in my '85 SD by hand, without removing the dash. Some have been harder than others, but I have done it.

__________________
Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

I am going for the pod removal come he!! or high water... thanks for the encouragement Michael.

__________________
'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique

I managed to pull the pod last night although I can't remove teh base that it is mounted to but I did manage to pull the rod back far enough to see that it was simply inserted into one fo the white plastic clips so i could reach in with a long screwdriver and get the rod out of the clip.
Since I couldn't remove teh whole base once i got the rod loose I was able to just extract teh forward portion of the pod which of course allows me to replace the diaphragm. I have another diaphragm from another pod that I pulled from a car a while back.
I have not put it back in yet but it looks like it is doable albeit it is not going to be easy.

I'll let you know if there are any tricks learned in this but the main thing that I found so far is that the surrounding tin, wires and vacuum lines severely limit your ability to get to this thing. However if you can pull it back far enough you can access the clip. I may have to go buy a long set of needle nose to get it locked back in.

__________________
'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique