Re: Type 44 Fresh air flap repair experiences?

[JordanVw@aol.com]

In a message dated 11/18/99 12:43:30 AM Eastern Standard Time, 
schulz@tif623.ed.ray.com writes:

<< Does anyone have either pictures of the flap and how to access
 it, or detaile dinstructions?  My archive search, using "air flap"
 turned up alot of references, but no real instructions.  I also
 looked at Scott Mockry's site, which also ahowed a drawing of
 the flap, but no detailed instructions.
  >>

i just did this on my '86 5kT.   the prob i had was that the vacuum bellows 
mount had broken off, and so the bellows (actuator, or whatever you call it)  
was just hanging there, and the vacuum line came off of it, and the evap 
flaps werent opening or closing. i also had the prob of the a/c blowing out 
the defroster vents. this was all fixed when i repaired the mount and hooked 
the vacuum line back up to the bellows. 

i bought a flourescent droplight from home depot to illuminate up inside the 
evap housing, flashlights are too hard to hold, plus you need both hands for 
this job.
Remove the glovebox, its pretty easy. every screw you have to remove is 
pointed out in the Bentley, tho its pretty obvious. then remove the lower 
door, so you can get at the broken mount.  i got the little "overengineered" 
U shaped steel official audi "fix it" bracket that fits over the broken mount 
part, from carlssen. (why didnt audi make the whole mount out of 1/8 thick 
steel instead of flimsy plastic in the first place?? must have been designed 
by team doorhandle..... ;<) 
next, i placed the fixit bracket in place, lined it up, locked the bellows 
back into it, then i used a finishing nail heated red hot with a torch to 
melt the screw holes in the plastic that hold the "fix it" bracket on, as 
there is not enough room to manuver a drill in there.
then i used some little sheet metal screws and a bunch of swearing, and some 
interesting contorsions, and somehow screwed the screws into the plastic.. 
 another thing to do, while you have all this apart, is to replace the evap 
flap seals.. the foam disentigrates over time, and air leaks around it, 
keeping the door from sealing properly.  i bought the OEM lower seal from 
carlssen, and replaced it while i had the lower door off, but i just used 
some regular 3/16 thick weatherstripping to reseal the upper door, as i didnt 
take it off. 
anyway, i put it all back together, and it works fine now..  until the spring 
mount breaks but im keepin my fingers crossed :<) 

chris
'86 5kT, TQ