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AC/Heating motors overhaul

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AC/Heating motors overhaul

Postby Isus » Thu Mar 02, 2017 11:18 am

Since I also have the ominous clicking sound coming from the depths of the cockpit, signalling that the AC motors or better to say the gears inside are shot, and I do have a replacement used set, so before I decide to tackle the task of dismantling half of the car, :roll: (Would the responsible engineer please stand up, so I may have a word with him) I wanted to check the condition of the replacement unit.
A dry run showed that they run fine, yet how they would perform with the cable attached no one knows.

The first task is removing the motor from the gear housing by undoing two screws
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After that is done, the white plastic retainer housing has to be removed, simply press the white clips inwards
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OK, now the housing has to be opened, one at the time the four clips holding the upper part of the housing have to be pressed simultaneously inwards and down,
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After the housing has been opened the gears are revealed, the problem lies in the three smaller ones, which are made from plastic. Also, the grease is old and not much is present I'd like a word with the engineer who thought of that. :evil:
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In this gearbox, the first small gear had a few broken teeth at two places. Luckily I figured out that the gears rotate only about 1/4 of a full circle.
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So after marking the damaged areas, the gear is rotated by 180° and put back into the housing, also "a little bit" :mrgreen: of grease is applied.
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After one gearbox is sorted time for the other, in this one the gear that was faulty in the first one is OK, yet the second one which is turned by the motor is damaged. Again rotated by 180°, put back into its place and greased.
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So now the only task left is taking half of the car apart and replacing the the unit.
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Re: AC/Heating motors overhaul

Postby pinino » Sat Mar 04, 2017 4:36 am

Don't waste your time replacing individual gears, find a used BMW stepper and swap the whole set, one half BMW with gear set with one half Alfa with lever and wiring. Take a look at this tutorial:

http://www.alfabb.com/bb/forums/164-168 ... s-r-r.html

See p. 10 for swap of gears. Due to their HVAC software, BMW gears don't get stressed out.
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