Date: Fri, 29 Aug 1997 08:51:17 CDT Subject: (Fwd) Revised blower replacement Author: Al Powell (http://www.ezlink.com/~powells/blowerfix.html) For the record, here's the fan/blower replacement procedure. Original from Eric Fletcher, modifications by Frank Bauer (fjb). I have eliminated the references to Eric's famous steak knife, as it's not really required. Notes I would add: 1) Remove all cable ties which appear to be in your way. The clipped ends on some of them really cut up my hands!! 2) You WILL need split ring pliers to get the split ring/circlip off the end of the fan motor. This ring retains the motor in the blower housing. This is obvious when you see it; it's on the driver's side of the housing. HINT: wait to remove it until you have the heat housing pried upwards. It's MUCH easier to reach then...but DON'T let the split ring fly off to god-knows-where when it comes loose! 3) Protect the fenders while doing this. You will be leaning over them a lot and jean rivets, etc can scratch them easily. 4) The old blower has a plastic cover on the back end. After removing the blower, if there is no plastic cover on the rearmost half of the motor, look inside the blower and make sure the housing has come out - it often sticks inside. If it's there, it will look like three wide fingers pointing toward the open side of the blower housing. Just reach in and pull it out - you can't put the new blower in place till this is removed. I have also added a few notes to Eric and Frank's comments. Original from: fjbauer@dsavm.e-mail.com Date: Thu, 18 Jul 1996 20:20:26 EDT Subject: 5000 blower and steak knives Subject: 5000 blower and steak knives Here is the post from Eric. I have made a few edits/additions - I just performed this procedure. (My changes marked with "fjb>") Frank Eric's post begins... Well I finally got around to doing the heater blower in my beast. With this method you only have to raise the blower box up about 3 inches, and it can be done in about half an hour. Al: If you don't have Eric's magic fingers, est= 2.5 hours. Tools required: 2 Flat bladed screwdrivers one short and one of the MONDO varitey. 1 Short Phillips head screwdriver 10mm socket 13mm socket 3" and 9" extender bar and Ratchet Outside Snap ring pilers Remove wiper blades with the 10mm socket. fjb>It's a 13mm fjb> watch for the spring washer under the nut when you pop the blades loose. Remove the black plastic shield with the Audi Logo on it. fjb> careful popping the clips or you'll crack the shield. Remove the wiper assembly (one bolt per wiper, one on the motor, one electrical connection) 10mm Socket here, You might want to lube the linkage while it's out.... fjb> You might want to vacuum all the crap out of the area at this point Al: DO IT!!! There is more crap in there than you'd believe!! Remove the Heater box Retaining strap with the phillips driver. Remove the Upper Radiator hose to dump about 1 quart of coolant and reinstall; this will prevent a mess in the next step. Remove the Heater core supply and return lines. Remove the Electric plug and Outside Snap ring from the back of the blower motor. Al: There is also a large washer - don't forget it when putting it back together! Shove the round Black Blower duct (passenger side) into the heater box. fjb> ...up to the bellows Take the small flat bladed screwdriver and run it around the seal on the the firewall to loosen it. fjb> just need to pry it loose here and there - enough so it will move some. Al: Agreed. It will come loose with a firm, persistent pull.... fjb> now go into the passenger compartment and remove the lower panels, console panels and footwell ducts from both sides. Also remove corrugated ducts for upper vents from both sides. Now everything will move freely enough for the next step. Take the MONDO Driver and pry between the engine bay firewall and the blower housing to raise the housing 3". fjb> raise the housing enough so that the Black Blower duct will clear the black A/C heat exchanger box. It may help to do some of this from inside the passenger compartment since there is much left/right clearance here. the blower housing can be tilted up slightly on the passenger side to acheive the necessary clearance. Al: I did all my prying on the engine side. Careful not to bend the firewall foreward of the heater housing, and DON'T pry where the AC tubing is under your prybar!! With the housing raised take the steak knife and cut the black blower duct so that it can be compressed on itself and slid futher into the blower box duct. fjb> ***skip the last step*** Al: Agreed. It can be shoved back far enough that this is unnecessary - You only have to get it clear of the AC box. Remove the 2 visible phillips head screws holding the blower duct adapter onto the blower housing. fjb> Rremove all three screws - you may need a long phillips for the lower one. Al: I don't see how Frank reached this with a long screwdriver. I managed it using a stubby Phillips and prying the heater housing WAY up. If I had needed to, I would have broken the screw free, but it was not necessary. However, I could NOT get the third screw back in when re-installing this part...so I just left it out. Eric: Take the MONDO screwdriver and break the lower screw out of the blower housing. fjb>[and Al] ***skip the last step*** Remove the duct adapter. Remove the blower motor cooling hose. Push the blower out of the housing through the duct hole. Install as they say is the reverse of the removal. Use the RTV or Silicone to seal the blower housing back to the firewall. That's it. I did this in Half an Hour by myself in 30F weather. fjb> skip the RTV part - add 1 hour to your time estimate. Al: Don't believe them. Allow 2-3 hours. It took me 2.5. And the sealant on the box was sticky enough that I didn't use any RTV - it appeared to me that the seal was still good. fjb> Wwhen lowering and repositioning the blower housing, make sure the oval rubber grommet/hose thingy on the bottom lines up with the opening atop the transmission tunnel. fjb> muchas garcias to stediric! Al: Lotsa Dankes to both gents!
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