Going to order the gears this week. Put the Orbital Kit in and it's a pain to change from cold to hot.

 

I have an 03, everything worked fine when I bought it used with 25k mi on it.

Knobs got hard to turn.
Broke off the shaft from one of the knobs. Yes, I know that sounds funny in a middle school way.
Replaced entire control unit, greased stuff. Still sucky.
Bought TSB kit, the expensive one. Installed all except the blender door itself because that required removal of the entire heater unit, huge PITA. Greased stuff. Still sucky.

I'm still forced to adjust the temp using the under-dash/steering column lever. Zone adjustment only changes between defrost (fortunately) and in your face, not feet ever (unfortunately). No simple "under-dash leverl" ghetto compromise to this issue AFAIK.

I'm at the end of my rope with this problem. I've come to the conclusion that after all the trials and tribulations that my cables themselves are just jacked and will never travel back/forth properly, maybe have lost their rigidity after almost 7 years of this BS.

So, my question is, where can I get JUST the cables, and how the hell do I install them? I really dont want to have to pay someone who has never seen under my dash in their life to deal with this to the tune of $50 an hour.

So sick of my eyes getting dry from the heat and freezing feet, and reaching under the dash while i'm driving to adjust temp.

Any help is greatly appreciated.

 

I solved the problem by removing the entire dash and installing the blender door. Belive me it worth the job. It is the only way out and at the end it is not that hard to do.

 

I NEED to know where this lever is!!!! I'm so tired of driving in the COLD! Pics would be lovely as to what i need to pull and push! Please help!

 

This is great news that I am not the only one with this problem. I can't adjust the temp, everything else seems to work though. I would also like to know where this lever is. lso need to get the new links, did someone post that you can pick these up at the dealer?

 

Just broke mine a few weeks ago, dealer wants 1.1K+ for fix, damnit all to hell...

 

It is a DIY work. Buy the whole thing at a Junkyard. All Lancer uses the same part. Just be sure it works fine before the re-installation.

 

@ alexisrc

Hey man, I read through the thread and many others on this issue.

I saw you actually did your blend door. I have installed the new lever kit, a new temp. control wire, and even a new HVAC control unit. Everything is installed correctly after a lot of research. However, it does not work.

My problem has to lie in the blend door binding. So my question is this, did you actually drop the dash and pull the heater box like the TSB states? Or did you find some other way? I'm reading the technical manual and the TSB and it talks about discharging refrigerant and recovering and it's definitely going to be $80 more in parts as well as engine coolant... =(

So was this simple or does it make it sound more daunting than it is? If so, what tools do I need?

- please.

 

I actually drop the dash and removed it all.
There is no need to discharge the A/C lines.
Remove the blender assy but not the heater core. You can dismantle the whole thing and put if back together using small screws. Clean the blender door and use grease . I recommend you to blend or fold the door it self using a heat gun, to make it sit better. You'll notice that the problem comes because the different shapes of the door and the rails. Test the blender door before you instal it back together. Round all sharp edges of the rails using a fine san paper. Grease and clean all gears.

 

Werd. Thank you. This is excellent news. My Evo is parked for around a month while my fundraiser for a new clutch is going on, so I have plenty of time to rip things apart.

 

@alexisrc

Did you have to remove the front crossmember (giant steel bar) under the dash to get to the heater control unit? Or were you able to remove other items, like the blower motor/evaporator and then pop the case off of the heater control itself?

 

Yes, remove the steel bar. Don't worry about it, it is hold by a few screws and it'll be easier to work with the unit.

 

Do you remember if you had to remove any of the wiring that was attached to the crossmember?

 

Yes, only need to remove the clips the holds them together. Take the bar out of the car. You need to work freely. To me alone using basics tools it takes about 2 days of patience work.

 

Remove all parts, including the blower and air ducts. Take the time to clean all parts, it should work like day one.