This is not really Evo specific but I'll start in this forum. When I bought my Evo (used) the one problem it had was that the cable that the AC temp knob actuates was broken.

So I replaced it.

It turns out, however, that the broken cable was a symptom of the real problem: whatever the lever actuates that the cable is attached to is friggin difficult to move. Ultimately the plastic lever motion rotates a plastic gear. This gear opens and closes something (a door presumably) that controls the amount of air that flows over the heater core (or something along those lines).

Unfortunately the investigation/replacement of this "white box" will require the removal of the dash. Im certain this is warrenty work but honestly Im afraid of what the dealership monkeys will do to the car while it is in their possession.

Has anyone else experienced this difficulty, and solved the issue in a relatively non-invasive way?

Thanks.

 

AFAIK, to get the the HVAC controls you only have to pop off the dash trim. I'm pretty sure that I've read about a screw to adjust the tension on the cable but I haven't done it myself. If my memory is correct it is under the controls so you may need to remove the cubby hole to get to it. I wish I could give you a more authoritative answer, but maybe a search would turn up some results.

 

Yeah my 03 was hard to move but the MR is actually easy to turn. This was one of the reasons I was whinning about no auto climate for US evo since everywhere else in the world gets the good stuff and we get the left overs I'd rather set the temperature and have 20 fan setting like the 05 STi and just chill

To remove.

Pull 3 knobs off. 2 screws hold the trim and pull off. Very easy. You'll see the white box.

 

You guys seem to have missed something in my initial post. I have already replaced the cable that actuates the lever on the white AC box behind the dash.

This means that I know how to remove the AC control cluster, and understand the operation of the steel cable that is connected to the temperature control knob.

This is not the issue. The issue is that the box that actually contains the heater core (the little radiator that the engine's coolant flows through, and the air destined for the cabin flows over) has a vent actuating gear that is *extremely* hard to rotate.

What is the cause/alleviation of this problem?

Thanks.

 

I could be a couple things:

- Some crap fell into your HVAC case (through one of the outlets) and is jamming the air mix door's movement

- Some damage has happened to the door linkage

Most likely, they will have to pull the whole IP to remove and disassemble the HVAC case to diagnose the problem. Personally, I think the thing is a real POS. Mine started out feeling nice when new, but after several months, the temp dial operation has gotten much stiffer and sloppier. My buddy's EVO did the same thing. I drove my other buddy's MR a few weeks ago and it was much better. I think they made some design improvement for the 05's.

 

mine does the exact same thing.......its like its really hard to turn, then all the sudden it breaks loose and is fine

 

go to your local dealer....there is TSB on this...it covers the lancers, evos, and outlanders.

 

my 03 is kinda hard to turn to... not that bad but a little anoying for sure.

 

So what is actually covered by the tsb? My heater core actually failed two nights ago filling my cabin with steamed coolant, covering all my windows. I bypassed it today but would like to see what the hell caused this.

 

I got mine fixed. The temp dial is a little bit better (not as good as I'd like). But the outlet mode dial is much, much lighter to the touch now. It was never a big problem before, but apparently this TSB changes the linkage for both of the dials.

 

I had the same issue with my '03. I've asked Mitsu to solve the issue under warranty.

First, they tought it was the cable, so they changed it but it did not solve the problem.
Then, they finally change the whole heat system in my car. It solves the issue. So it's seems to be more than a cable issue.

Results, my car is fixed. The bill for was $1600

So if your car is still under warranty, run to Mitsu. If not, I'm afraid you'll have to find by yourself.

 

The majority of this problem can be resolved just by the gears actuated by the cable on the a/c box itself. Don't have the part numbers of these gears any more but if you check the tsb at your dealership the gears themselves can be had for about $5-$10 depending on your relationship with your dealership.

 

I just did this fix on my 03

it involved removing the dash, draining the coolant and recovering the A/C


Here is the TSB that was being referred to.

https://www.evolutionm.net/forums/mi...hard-turn.html


Its not that hard to do if just a PITA to get dug down to the heater core area. After I was done it was good as new.

I think it cost about $180 in parts for the mixer door and the cabin filter and other misc stuff

 

Here's the deal. I've had to remove the whole assembly to replace my heater core. ONE week later I was made aware of this TSB and kicking myself in the a$$ over it all. I said the heck with it and just replaced the parts I could access easily, namely the two gears on the driver's side of the a/c box. Replacing these two gears that allow the cable to actuate the sliding door on the a/c box relieved a good 90% of the tension experienced in the assembly for me and several other friends I purchased these gears for as a gift