How To: Deluxe Heater Control Lever Replacement
 

Hello All!

Thought I would put together a quick tutorial on replacing the levers and cables on a Deluxe Heater Control unit. Pretty simple job that can be accomplished in about an hour once the control unit is out the truck. Hope this helps!

The problem - broken soft pewter control levers in the deluxe heater control unit
http://i1376.photobucket.com/albums/...psacbe6d8b.jpg

http://i1376.photobucket.com/albums/...ps161382c6.jpg

The solution - replacement steel levers from Old Air and new control cables (I purchased both through LMC).
http://i1376.photobucket.com/albums/...psd0d1c304.jpg

http://i1376.photobucket.com/albums/...ps576529f0.jpg

Step 1 - Remove the old cables by removing the 1/4" fasteners and retaining clips.
http://i1376.photobucket.com/albums/...ps05316414.jpg

Note - One cable connects to the front half of the lever near the control face. It is kind of pain to get to.
http://i1376.photobucket.com/albums/...ps000a4e6a.jpg

Step 2 - Remove the Defrost Hose Bracket to gain easy access to lever fulcrum pin.
http://i1376.photobucket.com/albums/...ps7c893b32.jpg

Step 3 - Remove the lower bracket and blower switch (the switch connects into a groove in the middle lever).
http://i1376.photobucket.com/albums/...ps0631bb0b.jpg

Switch Removed
http://i1376.photobucket.com/albums/...ps1c83a385.jpg

Pay attention to the bushing - the Old Air kit comes with a new one but don't lose it if yours does not.
http://i1376.photobucket.com/albums/...psca1e0f5f.jpg

Step 4 - Remove any remaining knobs (may have to brake them to remove them).
http://i1376.photobucket.com/albums/...psa27fac02.jpg

Levers ready to be removed - notice the distortion in the soft metal.
http://i1376.photobucket.com/albums/...ps9d3c0f09.jpg

Step 5 - Drift out the fulcrum pin (a few taps on the pin is all it takes)
http://i1376.photobucket.com/albums/...psaafaae2f.jpg

Components removed.
http://i1376.photobucket.com/albums/...ps65d37956.jpg

Control Unit stripped down and ready for reassembly.
http://i1376.photobucket.com/albums/...ps7efa9331.jpg

Re: How To: Deluxe Heater Control Lever Replacement
 

Part 2 - Going Back Together

Here are the parts in the kit from Old Air. It is complete and the levers are much more rigid than the original ones.
http://i1376.photobucket.com/albums/...ps4b8ee2b9.jpg

Step 6 - Assemble the lever arms and spacers. The provided instructions are good and provide adequate detail.
http://i1376.photobucket.com/albums/...ps42c0b699.jpg

http://i1376.photobucket.com/albums/...ps4dccbb9b.jpg

http://i1376.photobucket.com/albums/...psebce63f0.jpg

http://i1376.photobucket.com/albums/...psdc72e1d6.jpg

Step 7 - Install the new knobs (mine fit tightly on the new levers)
http://i1376.photobucket.com/albums/...ps8d7e0a81.jpg

Step 8 - Install new cables and reinstall blower switch and brackets . The new cables are much smoother but the cable end clamps suppled were inadequate. They did not match up well with the channels in the control unit. I ended up reusing the cable ends from the original cables on the truck. Also - the cable attachment on the front half of one of the levers is a pain!
http://i1376.photobucket.com/albums/...psf08ca677.jpg

Complete and ready for reinstallation. A simple, easy improvement to get the heat working properly! :chevy:

Re: How To: Deluxe Heater Control Lever Replacement
 

Thanks for taking the time to put together this nice write up :)

Re: How To: Deluxe Heater Control Lever Replacement
 

Nice writeup. I will be using this when I rebuild mine later this year.
Bret

Re: How To: Deluxe Heater Control Lever Replacement
 

Thanks for the kind words CaptainFab!

bj383ss - Hopefully it will be a help to you. I looked for similar information before I did mine but didn't find anything so I thought it might be useful.

Re: How To: Deluxe Heater Control Lever Replacement
 

Outstanding write-up! I like the pictures and the attention to detail. This really needs to be included in Woogeroo's How-To thread. Maybe you could shoot him a PM? I think that he would be glad to include it. If you haven't checked out that thread, you need to check it out. It's awesome!

Re: How To: Deluxe Heater Control Lever Replacement
 

Outstanding tutorial. I will be referencing this when I rebuild mine.

Since this was very good, I have added it to the FAQ for the 60-66 area. Thanks!!!

Re: How To: Deluxe Heater Control Lever Replacement
 

Thanks chevyrestoguy! I appreciate the kind words! I will shoot Woogeroo a PM.


Thanks chevy_mike! I have taken more than my fair share of info from this site so it is nice to contribute a little!