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Heater Cable Remove and Replace Tutorial with Pics
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62CdnNotch
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PostPosted: Wed Mar 16, 2016 1:54 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Ugh! The passenger one came out fine. The drivers side broke and is only sticking out about 1 inch. PB blasting both ends and letting it soak. Any other suggestions??
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wcfvw69
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PostPosted: Wed Mar 16, 2016 7:47 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

62CdnNotch wrote:
Ugh! The passenger one came out fine. The drivers side broke and is only sticking out about 1 inch. PB blasting both ends and letting it soak. Any other suggestions??


Odd, from what I've read, it's always the passenger tube that is a bitch to remove the cable from.

I read in one thread where a poster cut a section of the tube out cleanly using one of those very small pipe cutters that you turn around the tube. It's used for cutting copper in small places. Before that, he filled the tube up with PB blaster for several days to break the cable sheath free from the rust. He cut that section of tube out and was able to pull the tube and the cable inside free and out of the tube. He then put the cut portion of the tube back up and used hose clamps to hold it in place.
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62CdnNotch
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PostPosted: Fri Mar 18, 2016 3:03 am    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

That might be just what I need to do.. I have one of those cutters and never thought of that!

Thanks
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ChipWrecked
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PostPosted: Mon Mar 21, 2016 3:52 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Just wanted to add that my left cable was jacked up and rusted solid.

In removing, it frayed like below:

Image may have been reduced in size. Click image to view fullscreen.


The PO ran copper tubing along side, and abandoned the OEM tube.

In frustration and general need, I cut all of the cable tube out and replaced with this:

Image may have been reduced in size. Click image to view fullscreen.


I bought a 25' length here for about $25 shipped: http://amzn.to/1S1G9bC

The 3/8" OD tubing was near perfect size for this replacement... It slid through the original holes like OEM. It was a lil tough to hand bend, but the final install was successful.
I tried to use one piece at first, but it was too hard to feed (I could've lubed it better). Instead I fed two pieces; one from midway to the rear and one from midway to the front. I adjoined the two butt ends with an 2" piece of 3/8" ID tube section and tack welded as needed.
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pyrOman
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PostPosted: Tue Mar 22, 2016 6:35 am    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

ChipWrecked wrote:
Just wanted to add that my left cable was jacked up and rusted solid.

In removing, it frayed like below:

Image may have been reduced in size. Click image to view fullscreen.



Did the cable swap just this past weekend. Same deal! Mad

Both cables behaved the same way, pulling out just like in your picture, the driver's side one at least finally let loose and came all out. the passenger one though, was more stubborn and when it finally came out, it left some of the plastic cover inside the tube about a foot or so from the back! So I ended up cutting the tube right about there and with a piece of hanger wire managed to push the plastic piece out the back. I then use a small piece of hose to "mate/close" the cut tube back up. Cool

I did not find this thread beforehand so I wasn't aware of the issues regarding cable lengths. I order a set from eVWparts and it appeared to me that they had 2 different cables, one for each side. Well, one was WAY forkin longer!!! Was not going to halt the project so ended up cutting it to size and live with it! Confused
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62CdnNotch
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PostPosted: Tue Mar 22, 2016 1:27 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Man.. Mine is holding on for dear life. Might have to go the way of ChipWrecked replacing the metal tube. Thanks for that info..
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ChipWrecked
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PostPosted: Thu Mar 24, 2016 7:38 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

62CdnNotch wrote:
Man.. Mine is holding on for dear life. Might have to go the way of ChipWrecked replacing the metal tube. Thanks for that info..


It took about 3 hours to remove the existing tube and run the new. The key is to keep the bends rounded and to a minimum (no acute angles). I was able to hand straighten the tubing from it's coil packaging and used brute force to form over the beam. The tube diameter did not noticeably crush at all, and I had no trouble feeding the new cable.

Another benefit of this tubing with it's "copper" internal plating and zinc outside, is weather resistance. Being steel, there shouldn't be significant galvanic corrosion issues.
Plus, I'm considering using the extra length to make hard fuel lines - which is what this tubing was designed for.

Oh, and it's inexpensive.

Good luck.
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62CdnNotch
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PostPosted: Thu Mar 31, 2016 7:45 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

So I ended up doing a bit of both fixes. I cut the metal line just before the rear axle housing. The cable continued to be a P.I.T.A. I got the front part all the way out, but the plastic cover in the rear pipe would not come out. I had to replace the rear part over the axle tube. I used aluminum 3/8 line piping which was very easy to bend. I then used a stock hose clamp to connect the two together. PB blaster did work partly, but my cable did not want to leave the bus.

If your going to do this repair, Start a week before by spraying PB blaster in the metal lines and using compressed air to push it through the tube. Leave it for days and then work at it. Maybe repeat numerous times.

Good luck all and thanks for everyones help..
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Tcash
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PostPosted: Thu May 12, 2016 8:15 am    Post subject: Heater Cable Reply with quote

Heater cable assembly order - UPDATED PHOTOS

Heater cable housing repair

heater cable pipe repair
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Globespotter Premium Member
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PostPosted: Fri Jun 10, 2016 9:52 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Forgive my ignorance, but my 77 Westy - the actual heater flaps work ok, but the PO has disconnected the cables.

I can see the LH cable end by the LH Heater flap lever, but the dash lever(s) are not moving that cable so I imagine it needs replaced.

I can't see a RH cable under the bus at all.

Image may have been reduced in size. Click image to view fullscreen.


Which cable from which lever goes to each heater flap in the rear?

How does lever #2 change the flow from DEF to Front/Rear Footwells?

Or does one cable open both LH & RH heater flaps? I'm a bit confused and the Bentley Manual does not explain.

Edit to add:

http://myweb.tiscali.co.uk/freemefromthishell/vw/T2%20Heating.htm

This seems to say that the one lever operates both flaps which makes sense to me. If so, does anyone have photos or diagrams detailing how the cables connect under the bus?
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Tcash
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PostPosted: Sat Jun 11, 2016 8:24 am    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

This is a good one.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=

http://www.thesamba.com/vw/forum/viewtopic.php?t=322553&highlight=tutorial

http://www.thesamba.com/vw/forum/viewtopic.php?t=364624&postdays=0&postorder=asc&start=0

Keep warm
Tcash
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Globespotter Premium Member
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PostPosted: Sat Jun 11, 2016 8:51 am    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Thanks TCash. I found two of those, but not the first one, so it's very helpful. I need to pull the bottom plate off my bus so I can see what is going on under there. Probably a good time to pull the gas heater for refurbish at the same time.
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Tcash
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PostPosted: Sat Jun 11, 2016 12:28 pm    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

Globespotter wrote:
Probably a good time to pull the gas heater for refurbish at the same time.


You're welcome
Gas heater
http://www.ratwell.com/technical/Heating.html
BA6

Good day
Tcash
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alschnier
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PostPosted: Sun Sep 10, 2017 10:29 am    Post subject: Re: Heater Cable Remove and Replace Tutorial with Pics Reply with quote

I'm in the process of replacing my heater cable. Have the front side ready to go. Back end is ready w/ string except I can't seem to remove the white plastic grommet in the back. Any tips?

I tried pulling cable thru anyway & it won't budge.

Welp - I got it. I didn't realize that the outer piece was also snapped into the holder on the frame. Popping it out made all the difference Smile

Image may have been reduced in size. Click image to view fullscreen.


Of course, then my cable wouldn't come out.

I tried lube. Lube w/ ramps. Then the drill... and it worked! I did need to cut the cable a few times as I extracted each section, but ultimately it all worked & I've got a new heater cable installed.

Image may have been reduced in size. Click image to view fullscreen.
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