The defroster lever is broken off at the back of the unit (probably because of a frozen cable). I'm needing to remove and replace the control unit and probably the cables also. Radio is still present. Can anybody review the significant steps and cautions or refer me to a previous post or site for this process. 68/327/2 bbl/ NO A/C
VERY common ailment (broken defroster lever). You can get the lever from all the Camaro parts suppliers.
YES, the reason the lever broke was due to friction in the Bowden cable caused by a kink in the internal wire. Remove the defroster cable, lubricate, and straighten the "factory" kink on the defroster side of the cable.
I just did this. Take the dash center panel screws out from the bottom and lift the panel off the top retainer carefully, the retainer is plastic. The screws for the heater control are now accessible. I don't have a radio so I don't know how much harder it is with one in the way but, if not too much trouble take it out for more room to work. You might consider taking the seats out too, so you can be comfortable on your back.
On my heater control, the body of it was a little loose where it attaches to the face so I treated it to some epoxy to prevent it from possibly rattling:
I also had to straiten the kink by the defroster like Michael points out.