Lancia Motor Club

Hi. I've been reading the terrific report of rebuild by Norm Thomas.

Of particular interest at the moment is his work on the heater controls. I have one lever that has a broken stalk, another that doesn't move all the way and the fan switch has no tension in it and appears to be on slow speed all the time. Other than that it does all work.

I'm interested in learning how to access the heater controls to work on them, whether it can be done insitu and where to find an exploded drawing of the assembly.

Thanks, any direction would be appreciated.

It is a dash top off job I am afraid. Slightly more complicated on an S1 as you need to remove the side vents to access the m6 nuts.

Hmm. That job might have to wait. Busying my self with small jobs whilst I wait for DVLA to sort the registration. I have a current drain to sort and the interior light switch not operating even though the light works when the door opens. Suspect its the door switch.....not had much luck fixing electrical issues yet.

This is the diagram from the TAV parts manual.

That diagram explains a lot. I'd like to tighten nut 9, wonder if it would give some more tension to the fan switch. Not sure it it could be accessed from within the fuse box area or even with a very thin spanner through the switch aperture. Without knowing the mechanism I'm not sure I wouldn't make it worse.

At some point I'll have to take the dash top off, get all the parts and do it properly.

Thanks Norm.

I very much doubt it could be reached Howard, and I really wouldn't advise trying.  Some of the fibre washers in my car had largely disintegrated - see pic below showing mine as removed, complete with broken levers. I've also shown a picture of the rebuilt stack.   If your car is similar you will only compress the washers and cause them to break up.  Better to wait until you have the dash top off I think.

The pictures explain so much. We're you able to get spare washers and levers readily?

They were bought from Omicron, a most reliable supplier. Always helpful and willing to answer questions.

tightening the nut will not really help but you may just get access taking off the dashtop speaker cover. With Fulvias it is always best to do the job properly then it will last another 50years!

There is a dash top speaker? Didn't know that! Upgrading the radio and speakers is on the list!

Well there may not be a speak under the clip on grill....

the photo shows the fan switch from below. You have to remove it to be able to do any work on it. It is likely that the fiber/felt washer sandwiched between the lever and the flat washer needs replacing. Be very careful tightening the nut on the pivot. mine must have been cracked, because it broke in two. I used supa-glue to repair it. Seems fine now

I could see the fan control assembly when looking up from the footwell. Putting my hand into the gap blocked my view completely.

I taped a bit of scotch bright to the end of a long screwdriver and cleaned the contacts. Also taped a flappy  bit of wet and dry to the driver to clean the moving arm contact face.

Next was a squirt of WD40 on the nut/ thread. After a while I put a hand with a small spanner into the gap and by feel found the nut and gave a small turn to tighten.

I now have a lever that I can feel the steps of operation and a much more powerful fan! Very pleased!

Anyone know if the plastic ends of the heater levers can be repaired insitu? It all works but the top temperature lever has a broken plastic end. The lever doesn't quite go all the way to the left so it's possible it has been forced at sometime and broken.

Thanks you lot!

On some Alfa Romeos and VWs of the late 70s, early 80s, the plastic heater lever is simply a pushfit. If yu find one of those, it is a very simple, highly non-original solution to your problem. Andrea

If the heater matrix valve in the footwell is stuck or stiff to operate then the bowden cable operating it with top lever gets bent and it never works after that. Check the valve is doing something when operating the lever…. Otherwise it is a dashtop off job the to get to the cable and straighten it.

Thanks Andrea, Tim.

The heater valve moves nicely and the heater blows hot and cold on demand. It could be that the cable is 'too short' so won't go all the way to the left. I can live with this for now but I'd like to fix the lever. I'll look around as Andrea suggests. Sugru also comes to mind....

https://www.ebay.ie/itm/403553767429 (https://www.ebay.ie/itm/403553767429)

No connection to seller

I wonder how you fit them? Think I'll try and make one from Milliput or similar.

Could do with a picture of the top lever if anyone has?

Thanks
8

Here are some pictures of the levers.

Thanks Norm. Looks like the top lever is the same as the bottom lever, just inverted. I'm going to look into mould making so I can model one out of Milliput. It's a small part that doesn't affect the car greatly, but I do like a project.

Wow, a full set of unbroken levers for a Fulvia. Now that’s a rare sight!

Two good ones came with the car, two are courtesy of Omicron!

It will be interesting to see how you get on. For information, my top and bottom levers (the same part as you say) were bought from Omicron for £38 each a couple of years back, plus vat and shipping of course.

Here's a few pics of my job to add an end to the heater lever.

First make a cast of the lower lever with 'Blue stuff'. Heat it in hot water and it goes soft. When cool it goes hard. Ish.

Use Milliput in the mould to make the part.

Clean up the lever still fitted to the car. Used a Dremel, carefully.

Slot the new end with a Dremel. Should have been a dentist. Glue it on with epoxy, leaving the sides clear for more Milliput.

Glued on.

Can't find the pic of the finished job! Tomorrow!

Here it is. Not perfect but until I have to dismantle the dash top I'm happy.