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No air from floor panel (broken shaft).

posted by  jbogusz on  Fri Feb 28 13:43 CST 2003
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I have 850 97 T5 with climate control (this is important). I guess I found why I do not have air coming from floor panel. Following advice from this web-site I took out glove compartment glove looking for broken arm. I could not found any. I found damper motor (floor/ defrost damper motor). So I took out three screws and there was some kind of shaft from damper motor to climate control box which was suppose connect motor with something in box to open/close floor panel. This shaft- short piece of black plastic was cracked and when the motor turned nothing really happened. Looks like the motor works fine (but you never know, because this shaft was broken. I took the broken piece of shaft to dealer, but they could not find part like this .The brought me arm someone was talking about on this forum, but it did not look like my part. Finally the brought mechanic who told me that this small piece of plastic is part of whole box-climate control box. (cost around $600 and needs 11-12 hours of labor. Does any body know what I am talking about? Does anybody experienced repair like this. I don’t belief that Volvo engineers designed car this way. I mean when the damper motor goes bad and plastic breaks you have to spend 12 hours and $600 to repair plastic which looks like $2 a piece. May be I do not know how to remove the broken portion form box. The hole plastic may look like 1 -1.5 inch long with diameter of pencil, empty inside , from one side going on piece coming out of motor ( the piece which turns ) the other end goes inside (this side is still in box , I did not know how to remove it). If anybody knows anything about this please help. THANK YOU VERY MUCH!!!!!!!!!!!








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    No air from floor panel (broken shaft).

    posted by  someone claiming to be bugman on  Mon Jun 9 15:18 CST 2003 [RELATED]

    Here is a fix I suggested to someone else last year. This cost about a buck and took a couple of hours. Ed

    raig,

    I just repaired this in a 97 850 wagon. You need to get under the dash from the passenger side. Instructions and pictures for this can be found in the Haynes manual and at Bay 13 http://www.volvospeed.com/volvo_performance.php.

    Once you get the glove box interior removed you will be able to see the damper motor (black, about 3" by 2") screwed onto the air duct to the left side of the glove box compartment. There are 3 #15 torx screws that hold it in place. Remove these screws and pull the motor to the right (you don't need to disconnect the electrical connection). When it is pulled away you will see a short, 4 sided, brass-colored motor axle that fits into the plastic damper axle. My damper axle was split longitudinally so the motor axle would just spin inside the damper axle without moving the damper.

    Go to the hardware store and get the smallest hose clamp that they have (the stainless steel type with the screw tightener). The one I got was about 1/2' in diameter when it was wide open. Fit the hose clamp over the damper motor axle and tighten (not too much since it is plastic, just enough to close the split). Move the damper axle with your fingers to make sure the damper can travel fully from stop to stop and the screw on the hose clamp will not impede the travel.

    While the motor is still unmounted, turn the car on and select the defroster position (knob pointer straight up). This will position the motor axle in the correct position. Slide the motor axle into the newly repaired damper axle and replace the torx screws.

    Ed








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    No air from floor panel (broken shaft).

    posted by  someone claiming to be bob on  Fri Feb 28 17:04 CST 2003 [RELATED]

    The good news is the part you need is relatively cheap and IS available seperately. You do not have to buy the whole air box. Now the bad news. The dash and climate unit have to be removed, and the box halves seperated to replace the shaft. There is a TSB outlining the repair.







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