Air position selector switch

[rogerd63]

2005 T5. Just wondering if anyone has had the selector switch for the demist/legs/shoulders etc play up?When i go to select shoulders it is really hard to turn and although it does go past the shoulders point it stays on demist.I can select the legs or combination of legs/demister or demist.
Not sure if a vent is jammed or something? Any ideas or how to sort it out would be great.
Thanks
Roger

[BrianJ]

I have heard that on early models, that switch has no stop, so you can keep turning it in the same direction until the cables get twisted up. I suspect if your careful you may be able to unwind it back by turning it opposite to your normal way watching for it to become looser, until you find the loosest point for any direction of turn.

The prevention is to always turn it one way to reach some setting, then turn it back the opposite way to return.

If this fails the cables might need a bit of spray lubrication.

Brian

[rogerd63]

ok cool il give it a try. I dont change it that often but this could be the case.

Roger

[Sunny43.5]

No I dont think thats correct as the way they work is usually the turn knob can be rotated in all directions continuosly as there is an unusual geometry in the way it works but the cable that is attached to the rotating part gets jammed inside the plastic guide tube and as I have replaced similar one in my sons van they are an absolute mongrel of a thing to dissasemble . If I remember correctly the actual turning knob is geared and drives a second disc that has the cable attached and the way the cable is attached it can continue to rotate as the actual cable does not turn or twist it only slides inside the tube Howard

[rogerd63]

The funny thing is that i can select the other settings like feet /demist/ and the combination so its not like the cable is jammed.It just wont go to the head/shoulders positon,well it does but it doesnt change over to that setting only.
I wonder whats inside the airbox that has a flap or whatever that changes over each setting .
Whats the best way to get to the airbox? Maybe something is jammed on that selection position?

[Sunny43.5]

Hi Rogerd63 as I said I have removed and replaced one of these units in my sons T4 but they still work the same for T5 and I only remembered today that there are more than one cable attached to the same disc there are usually two so as the disc turns it opens one vent and close another as I said it a complicated mongrel thing to dissasemble My work T5 has more kays than our family T5 yet mine rotates perfectly but our home van also sticks and does not send air to where it points . The main problem is that the knob has a small gear on the back side it then drives a horizontally placed disc the cables are actually a single strand of a hardened wire inside plastic or nylon tubes there is virtually no lubricant on these cables so if they get sticky they jam and then the gear will skip a few teeth and get out of alignment . The main problem with removing them is that there are also heat and vent cables all on the one fitting and getting access to them is really awkward , to remove and change my sons one I had to crawl up under the dash and discconect the cables first then you can pull the unit out be very careful as the cable ends on the control unit are held in place with metal clips over plastic and are ver yfragile . Howard

[rogerd63]

Thanks Howard, maybe one day when im absolutely bored il have a go then .Sounds very uninviting haha.

---------- Post added at 06:49 PM ---------- Previous post was at 03:57 PM ----------

ok ive had a go at it and its a nightmare under there! Not sure if im going to worry about it but im sure its going to annoy me as long as its broken.
On a brighter side ive installed two armrests on the passenger seat which i got off ebay UK. Very happy about it and they are a perfect match.Not too hard to install but it did require the seat to be removed.Easy as.

[gregozedobe]

This is a common problem with T5s. IIRC VW's "fix" was to change the selector dial so you couldn't move it between the 12 and 9 O'clock positions on later build T5s. The original braided cable is very prone to kinking, but it is possible to fit a different cable that is one piece wire that is more resistant to kinking. Do a search over at the UK Brick-Yard forum for more info and photos and part numbers.

[rogerd63]

HI ,well after a search on the Brick - Yard site ive found a good article on the fix method. So ive done it and found the cable which operates everything was bent at the lug which connects to the selector dial.I straightend it out and lubricated the cables etc.It now works fine but it will kink up again if i go all the way to full demist. 12 oclock. If i just go from 9-6-3 oclock theres no problem.I am going to live with this as its all i really use and it still gives demist with the feet on too at 9 oclock.The solution is to buy the new style cable which is like piano wire but as they say its a bigger job to repair as you have to take out the glove box too.
It took me about 30 min to get it done .Nothing too hard just careful patient hands.Check out the link ive posted from the Brickyard.

How to fix your heater cables [improved!] - The Brick-yard

Hope this helps someone else.
Cheers
Roger