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Discussion Starter #1 (Edited)
Old Blue went under the knife today to fix inop stepper motors by pulling a modified version of Alfa TSB Alfa 164 TSB 80.93.02 and Alfa 164 TSB 80.94.01

Turns out somebody has been there before me and car already had brass ring on air distributiion drum and the latest 60610100 stepper assembly (Bosch 0 132 010 322) but neither motor worked as somebody had glued on front motor for air drum without mounting screws and jammed a piece of old hollow lawn garden hose in along side motor to hold it in place and guess it didn't work and gear on motor not engaged into gear box.

Not sure why rear temp motor wouldn't work, but appeared motor gear not engaged either as I could move temp lever back and forth from false firewall side and lever moved on gear box. Opened gear box and all gears look good reassembled it and test with power and it works.

Plugged in another stepper to test a/c panel and system wiring and that all checks out.

I managed to get the stepper assembly out with out pulling dash as front end not engaged correctly and I got rear two screws out through openings in glove box without cutting any thing.

But that is where my luck ended so I did the TSB procedure of removing enough stuff and screws to pull back right side of dash and get the defrost ducts out so I can install good stepper maybe tomorrow.

Wore my blue "surgical" gloves and removed the mushy black foam bricks without to much mess.
 

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Discussion Starter #2 (Edited)
Installing stepper motor in Alfa 164

Tomorrow another day.

Tomorrow has come, installed good used working stepper motor and put dash back together. It is amazing how easy it went back together. Well almost together. I have to correctly install better vents in the ends of the dash as they were already broken before I started project.

May have good spares somewhere, if not I will get them out of Sara's wrecked 164B.
 

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So are folks generally just taking the old foam blocks out and leaving those areas empty, or replacing the foam with other types of new foam. It's just there for sound deadener, right? I wouldn't mind more engine sounds. ;) I've never seen any other manufacturer using so much foam under a dash anyway.
Charles
 

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Discussion Starter #5
So are folks generally just taking the old foam blocks out and leaving those areas empty, or replacing the foam with other types of new foam. It's just there for sound deadener, right? I wouldn't mind more engine sounds. ;) I've never seen any other manufacturer using so much foam under a dash anyway.
Charles
I cut some foam bricks from a stash I got of scrap foam from mattress factory located just up the street from my house. I just stuffed in about 3 pieces.
 

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With my restoration project currently in progress I just completed the dash job, replacing the existing stepper with the one from the donor car.
Someone had been there before me as there was very little foam, or it had all dropped out over time.
I tend to think the former as I found other signs of previous entry....

I did not know whether or not the existing stepper was original or not, or good or not so I replaced it knowing the donor stepper was good....

The stepper I removed has BOSCH number0132010316 with a little 917 tagged on the end.
Does anyone know whether that is original or a replacement?

I installed foam cut from the usual yellow regular density pieces I had in the garage.
 
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