2G How to disassemble your 2G HVAC unit (without breaking it)

2G DSM HVAC DISASSEMBLY​

I’m sure by now, most of you know how to remove your HVAC controls from your car (HVAC= Heating, Ventilation, and Air Conditioning, for those of you who didn’t know what it actually stood for). There are also plenty of you in this community who know how to take the HVAC unit apart, and have probably done it by trial and error, as I have over the years. But for those of you that have never done it, let me try to save you some headaches with this write up. If you’re wondering why I’m writing this up, it’s because I see so many people wanting to know how to add LEDs to their interior parts. I’ve been asked about this before, but never wrote it up, so… enjoy.

TOOLS NEEDED:
Flat head screw drivers (x2)
Machinists scribe or small pick of some sort
A lot of patience
Case of beer (optional but recommended)

STEP 1: Easy and simple (sort of), remove your control unit from the car.
I’ve seen this done 2 ways, both with their own level of frustration. Disconnect the linkage from the unit, CAREFULLY, and disconnect the wire connectors and pull out the 4 screws in the front. Now, you can either pull the unit out through the stereo area, or you can pull the dash out, then pull the unit. If I’m pulling the unit from a salvage yard, I leave the dash in, but if I’m doing this with my car, I pull the dash before even pulling the linkage from the unit. Anyway, once the unit is out, you can start disassembling it. Now would be a great time to clean it too, mine was dirtier than ones I’ve yanked from the salvage yards.

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STEP 2: Pull off all the easy to remove parts that you don’t need tools for.
*Cold air on/off button
*Stock lighting connection
*Air speed selector knob
*Vented or recirculated air selector knob

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Back when I did all this the hard way, I didn’t know the knob can just be pulled off the vented/recirculated air selector. I would always try to pull the entire arm off of its pivot point on the underside of the unit, circled in red. I didn’t matter how careful I was, or what method I used to pull it, I would break the plastic tabs every time. I encourage you all to learn from what happened for me, just pull off the knob, and you’re good to go.

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STEP 3: Pull off the 2 large rotory knobs.
This involves some patience, which when I did this the first time, none was to be found and I nearly threw the unit at the wall. Rotate both knobs all the way to the right so you can see the backside of the knobs without the adjoining linkage pieces interfering.

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Take your screw drivers or pick, or both, and pry the tabs of the knobs inward. You’ll have to also push inward on the knob at some point to release the grip of the tabs. This is an absolute b!@#h to do, but can be done. You may want to start drinking those beers now…

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For the knob that adjusts the temp, you’ll just have to play with it until you’re able to pull the knob out. However, on the knob for the airflow direction, you can cheat by placing one screw driver as I have, circled in pic, and then you’re free to leave it alone while you pry with the other screw driver and yank out the knob.

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STEP 4: Removing the front cover.
Now that all the knobs are removed, you can pull the cover off, but try to do this without cracking it. The plastic isn’t as pliable as other plastics used on our cars, but can still be done. You should invest in a beer refill right now if you haven’t already. Take a screw driver, I suggest a smaller one, and pry up on one of the 3 tabs on the top. I always seem to start on the left side of the unit, but you don’t have to. Pop the 3 tabs on top in this fashion and the side ones will either pop out on their own, or be nearly there.

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On the bottom side, put your screw driver in between the 2 tabs that are next to each other as I have.

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Popping these tabs, should pop the 3rd bottom tab automatically. Now just slide off the cover and you’re finished. The inside acrylic piece can be removed if you are doing LED mods, but if not, leave it there. If you’re replacing the electrical unit for the air speed control, remove the plastic nut holding it on from the inside and pull the component off.

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[spyderdrifter]

Ok, I don't know why my pictures aren't being displayed. I'll be looking into it and this will get updated when it's all figured out. If anyone has an answer on how to fix it, please provide...

FIX IS IN PROGRESS, thanks for being patient.

And now I can't delete this post. Oh well. Problem was fixed. Thanks Chris.