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absoffthewake -> RE: air only from defrost vents (1/13/2008 11:21:03 PM)
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I Figured this one out!
The problem is with a servo that opens & closes the flap that redirects the air. It is located directly above the accelerator pedal (there's 2 identical servos). What happens is when the computer recalibrates the servo to find the min & max servo travel, it puts alot of stress on the gears that control the servo arm when it reaches the min & max of the travel. After repeated calibrations (ie: disconnecting battery) the gear gets pushed away from the toothy portion of the shaft the main gear is connected to, therefore it slips. Becuase the gear slips, the computer cannot determine the min & max travel, so it drops back to the furthest position (where it directs the air to the footwell & defrost).
You can fix this 2 ways.
#1 and probaly most common, replace the servo.
#2, the free way, open up the servo (real easy) & push the gear back into place. Removing & installing the servo is difficult, and requires a small ratchet with a very long arm. Aligning the gears when installing the servo is also difficult. The servo arm has a notch, and the gear has a pin that must go into the notch. Install the servo loosly and get your fingers in there and feel the pin & notch into place. Since the gear's been pushed out once, I guess there's probably the possibility of it not lasting as long as new, but its a great way to buy you some time (maybe another 4 years!)
I must say that it almost looks like it was designed to fail.
Hope this helps someone!
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