Broken Shaft - Complete Repair Kit

Broken Shaft - Complete Repair Kit

This kit includes everything you need to repair a broken shaft in the heater box.

Typical fault codes:

801189 - Engine mixed air right: Initialization fault

801126 - Engine mixed air right: Initialization fault

Kit Contents:

• Drill guide
• 29mm Hole Saw
• Replacement shaft
• Stop insert

Optional:
For added stability, you can use a bonding material, such as sealant or glue, on the flap/shaft assembly.

Tip:
To save on costs, consider purchasing the 29mm hole saw locally, which will reduce shipping fees. Then, order the "Broken Shaft - Repair Parts and Drill Guide".

Installation Steps:

1. Remove the trim panels to gain access to the actuator.
2. Disconnect the actuator’s electrical connector.
3. Remove the actuator by unscrewing the two screws.
4. Verify that the shaft is broken (the shaft can rotate more than 70 degrees).
5. Install the drill guide.
6. Use the 29mm Hole Saw bit to create a hole (without the center drill bit).
7. Remove the drill guide.
8. Clean the area inside the heater unit by vacuuming all debris.
9. Clean the edge of the now-visible mixing flap.
10. Check the shaft orientation (there is a ridge on top and a rounded section at the bottom—shaft should point downward).
11. The mixing flap can be as on the picture and must then be rotated Counterclockwise to the position on the second picture.
    
    
12. Install the replacement shaft, pushing it into place until you hear a click. (Sealant or glue can be applied for extra bonding.)
13. Ensure the mixing flap rotates smoothly by rotating the shaft.
14. Install the stop insert, ensuring the shaft is correctly aligned and positioned. Refer to the provided image for proper installation depth.
    
    
15. Reinstall the actuator and reconnect the electrical connector.
16. Reattach the trim panels.