I'm in the process of replacing the evaporator in my 95 E300 and have an issue that may be easier to resolve by modifying the automatic part of the system.

I've attached a shot showing a plastic "tee" piece that has one of the connectors broken off of it. Seems it controls the main air damper and is only available if you purchase the complete box. I'm not going to purchase a complete box and am considering modifying the system to do away with it altogether. It looks like the damper this tee is used with is set up to open/close recirculated air. Well, being in the part of the country I am in during the summer time I really don't want any outside air when it is 90+dF ambient. With that said, I do cruise occasionally with the outside vent on (no compressor) if it is nice outside.

The reason it has gotten me to thinking about it was that I have ridden with ppl that never turn the recirc air off. If I don't shut it all the way off I may just set it up where it is fixed ~20% outside air position. Can anyone think of some negatives to making a mod such as this? The car is coming up on 300k miles and I don't ever see myself getting rid of it unless I part it out.

If anyone has the piece shown in the pic that is intact I'd be interested in it.

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Jim

I agree with you. I'd have recirculate on permanently if I could. If I want outside air I'll open an window.

- Peter.

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2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

Yep, there's a disadvantage -- windows will fog like hell on any humid day where it's too cool for the A/C to cut in. Why not drill the broken end of the T-piece and run a bolt through to have something for the link to pivot on?

Thanks - that is the way I'm going to repair it if I can't find a good one or don't fix it.

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Jim

Looks like a bellcrank from a model airplane. Visit the hobby shop, maybe cut one from metal.

I didn't know that you was a "Shade Tree" Mechanic.

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Jim,
How deep are you into this job and how is it going for you? Curious to know how much time you've got into it so far and how much time you estimate for the entire job. I have to do mine, but I'm just not ready to commit.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

Pics of the carnage!

10 am to 5 pm to get here. It is not really that bad of a job in my opinion. You just have to take your time and be methodical about it.

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Jim

Thanks for the pics, that's only a little worse than my w126 when I had the interior out to replace a snapped e-brake cable..not that I want to get that deep into a car again. Still, I need AC in the summer with the black/black car, it's working nicely now but I know it'll be a matter of when, not if, the evap needs replacing.

Alright I've got all the input from the OD side now how bout some input from the folks that don't visit OD.

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Jim

Things have been kind of slow in the shop so I was able to get everything buttoned over the past couple days and get the car back in operation. I've kinda missed having this car in operation and am glad to get it out of the shop. The only parts I came up missing was the plastic surround piece that goes around the gearshifter.

I modified the climate control system where the recirc damper is "fixed" at about 10% open (outside air) and will have to be adjusted manually by going in through the blower. We'll see how this works out. It will freeze you out now but it is not that hot right now.

There is the world of difference between the way this car performs and the way the gold E300 performs. This one accelerates alot better than the gold one.

This job in the 124 car is easier than a 123 car to me.

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Jim