I've got a replacement FAN control lever and I started taking the control head apart. At one point, you have to remove the chrome face from the unit to get the black plastic slider deal out to remove the broken lever.

The replacement instructions WARN you that the chrome face is cast and the 4 tabs may break, so be careful. Like I needed them to tell me that.
I've been very gingerly trying to pry the corner tabs and they won't move. I already chipped the corner of one.

Any tips for getting the chrome face off so I can get the broken lever out? It's already been removed from it's arm by just breaking the slip-washer off.
Ideas? Man, I don't want to have to epoxy the face back onto the rest of the unit.

[ 12-18-2004, 03:47 PM: Message edited by: HwyStarJoe ]

I've been down this road, replaced the middle lever on my 69 unit. Since my car is in paint jail I still have the control unit here (half way done with installing the vintage air system in the car!)
Anyways, I was as careful as possible, slight bending the tabs and one did eventually break, but its ok, if you alright with repairing you can purchase some 30 Minute Epoxy from the hobby store, its strength is much stronger than the metal tabs originally used, so I have 3 tabs still existing and one tab that was damaged, I used 30 min epoxy on all 4 just to make sure its held in well.
As to trying to remove without breaking, I slightly bent all 4 using a small flathead as a lever inbetween, once I got them all bent slightly out of the way, you can then keep one side deep in its edge, while the other side you attempt to pry out, gently bending the metal out of the way just enough to pop that side out.
Reinstall the opposite way, installing one side then using a small flathead to help push the other side back into its final resting place, then bend the tabs back in. But I am telling you, these tabs are very weak, the metal is too old and its not strong metal in the first place, some really cheap nickel alloy of some sort, thus I had to use 30 minute epoxy to tighten things up. Btw, while you have it apart, use some white lithium grease on the plastic sliding areas and the metal levers to make it smooth as silk! You should also consider a new clear faceplate and template if yours is getting cloudy/colored/faded.

http://69camaro.nextmill.net/temp/fancontroltab.jpg

Some one on this board once said that they heated the tabs up with a propane torch and they bent easily but I don’t recall if it was a 67-8 or 69..

Thanks Brian, Ron

After a combination of a small blade and large blade screwdrivers, I got it off, but I only left myself 2 tabs that will still work. I saw no other way really. One of the first things I thought of this afternoon was to use heat, but I already knew it was cast to begin with. I was afraid they'd just break anyway.
Not a big deal. I always have JB Weld as a backup.
graemlins/thumbsup.gif

Joe, I made a replacement black backup-- you know the part between the body of the control, and the plastic face... the one that's all shriveled up.

I made a couple of extras, if you need one. Just lemmeno.

Thanks for the offer Gary. But unlike most of the other parts of my car, the interior was pretty tight when I got it. I can re-use mine. Even the clear plastic is unscratched. Go figure!

I normally don't endorse jerry-rigging anything, but I was relucatant to take apart the assembly so I fabbed up a two piece splint made of aluminum that tightly surrounded the entire broken area on the lever and bonded the splint to the lever with two-part epoxy and clamped it until dry. It is good as new and I thoroughly tested its strength before re-assembly. It would break somewhere else before the repair would give. If the cables and pivots on the flappers are well lubed, there really isn't that much stress on the lever. Just thought I'd throw out this info for someone looking for an easy fix.