Broken Lever - Team Camaro Tech
Heating & Cooling Heating, cooling and air conditioning

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post #1 of 7 (permalink) Old Jul 27th, 18, 08:56 PM Thread Starter
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Steve
 
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Broken Lever

The top lever on the heater control assembly is broken. I don't see a replacement for that lever in any of the parts catalogs (I do for the bottom De-Ice lever, but not the top one). What are my options to get this fixed?
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post #2 of 7 (permalink) Old Jul 28th, 18, 09:45 AM
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If I remember right the levers are interchangeable with other 67/68 GM units, maybe the Chevy Nova and Trucks? The trucks levers are reproduced and available on-line.

As to fixing, I assume it broke because the cable is un-lubed or rested in place or the control door flap on the heater box is jammed or hard to manually move. So that would be step one, then you can see if it can be welded together but most of these parts were made from foundry "pot" metal formulations which was whatever was left over in a pour was thrown into the "pot" and that mixed metals consistency was used for a whole host of metal parts. So often very hard to repair, but not impossible. Sometimes you can drill small holes on the existing lever ends, then make a splint of sheet metal and then wrap that around the break with enough surface coverage over the good metal to drop two pop rivets on each side of the break to the two ends. Problem is that the splint has to be strong enough to take the force, but thin enough to not interfere with the other levers.

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post #3 of 7 (permalink) Old Jul 28th, 18, 09:51 AM
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Nova is definitely interchangeable. That is what I used. Where exactly are you located? I probably have a few laying around. You in the states?
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post #4 of 7 (permalink) Old Jul 28th, 18, 12:04 PM Thread Starter
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Re: Broken Lever

Thanks for the info -

I'm in Orange County, CA. I tried to move the the top lever assembly by hand and its very difficult to move so I can see why it snapped. I would need to lubricate those cables before replacing the lever. How big a job is it to pull out the whole assembly, cables and whatever else needs to come out to gain access to be able to lubricate the cables and the doors that they control?
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post #5 of 7 (permalink) Old Jul 28th, 18, 01:32 PM
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Its not hard to do. Might want to just replace the cables. They are not that expensive.
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post #6 of 7 (permalink) Old Jul 28th, 18, 05:32 PM Thread Starter
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Re: Broken Lever

OK. Took your advice and pulled out the assembly and the cables. I tried the door flaps and they are pretty easy to turn - so the problem is with the cables - which I think are not original. So will lubricate these and see if I can get them to function more smoothly.... if not will buy new ones.

I added a few pictures of the broken lever - one shows how it should look, and the other where it snapped. I'll see if I can find the matching Nova or truck lever as I agree that the metal looks very brittle so will look to replace rather then try to repair the lever.

Thanks again guys for the advice and guidance.
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post #7 of 7 (permalink) Old Jul 28th, 18, 06:44 PM
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Re: Broken Lever

On my 1967 Camaro I utilized the splint method on that same lever about 20 years ago. Its ugly but functioned great. Fortunately, I switched to a vintage air GenIV A/C which allowed me to get rid of the cables.
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