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93 Carry Dash disassembly

Discussion in 'Suzuki Carry' started by 329049Carry, Oct 28, 2020.

  1. 329049Carry

    329049Carry New Member

    We recently started cooling off allot, plus the typical NW rain, went to run the truck found out no defoggers.
    Lever wouldn't budge, reading the forums, probably a bent cable... nuts.
    Ran the truck from cold, the heater core hose was warm (coolant flowing) while the main radiator hose was cool, a good sign the thermostat was Ok. no heat out the vents...
    Tore the dash apart, not a terrible thing to do, lots of screws and pretty straight forward. Found the bent cable, also found, watching all the dampers, my truck blocks heat out the vents, heat only goes floor and windshield. My truck also has AC. Just surprised no vent heat.
    I was able to straighten the cable and it still works. Tried it several times. We will see how long it lasts, probably not long from the reports others have left. In the mean time I will search for a replacement.
    I don't think I had to remove the whole dash (hindsight), as most of the controls you can get access to through just the front pieces, but I would still need to drop the steering wheel, but that is just 4 bolts.

    Attached Files:


    SAITCHO Active Member

    Thanks for the pictures. Can you lube parts in there so it does not grip and bend the wire again?
  3. 329049Carry

    329049Carry New Member

    Actually the steel wire is just in a hard plastic tube. I think adding any type of lubricant would tend to pack in dust and jam the wire even more. The plastic tube actually works quite well, I think what happened is the actual mechanical damper jammed up at some point and someone tried to force it. Hard to say on a 25+ year old truck.
    I also think I would just have to replace the wire if need be, although the 90 bends at the end for the attachment to the controls might be difficult without breaking the wire.

  4. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    I used to have special tools for bending the wire, and putting loops on the ends as needed. No idea where they went.

    You might be able to find a pair, on eBay. But, I’m betting that anyone who knows what they are will want a fortune for them, and those who don’t know what they are, won’t be able to describe them well enough that you could ever find them in the millions different pliers on the site.
  5. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    DuPont makes a lube with teflon which goes on as a liquid and drys to a medium hard wax. I use it all the time because it doesn’t attract dust.
  6. Limestone

    Limestone Well-Known Member

    Yeah when I had my dash apart, I addressed all that while I was in there, cuz I didn't plan on taking it apart again any time soon! Yeah Jigs that lube works great, and the atv suppliers actually make a clamp type gizmo that goes on the cable housing, and you squeeze the lube through a long stainless steel needle, into the cable, and it works pretty good! On all of my metal control brackets, I sprayed some dry film graphite spray, on all the contact points, and everything is working nice and freely! To me these are the preventative maintenance things that are pretty easy!
  7. Troy Groeneveld

    Troy Groeneveld New Member

    Did you find a way to allow the vent to blow warm air when you were in there? That has been a deal for me as you stated, for the past 10 years. I would love to resolve that problem for all of us.
  8. Troy Groeneveld

    Troy Groeneveld New Member

    Also for the air filters. I see the center filter off the duct. Explanatory. What about upper glove box area? Is that another.
  9. 329049Carry

    329049Carry New Member

    There really isn't a way for me to do it. The damper flap (valves?) are somewhat large baffles, that as soon as you move the lever from vent, closes the vents off. I found you can put the selector lever in between different modes and control the air flow better, just not through the vents. The damper box looks like a real PIA to open and mess with. I also have the AC unit, but I think the heater portion is just like all the others in this series run.
    I actually have found the heater to be really good, once the truck warms up, where I would rather have it on my feet anyway.
    One of the good things about a small cabin, really doesn't take much to warm it up.

    Limestone likes this.
  10. Koffer

    Koffer Active Member

    I’ve probably replaced 30+ of these cables and what happens it the flaps get sticky and stuck , and then bends the cable right at the side controller. If you can clean and lube up the linkage on the heater box and clean up the inside the cable tube you’ll be ok but once that cable gets bent it will bend again easily. First one I did took me like 1 1/2 hours , I can now change them in 15 mins . The cables are still available from Suzuki ( they were dirt cheap up to around this time last year) here’s the part number E39B1553-CC0F-47DA-ADE3-1A2AD432716E.jpeg
    Limestone likes this.
  11. 329049Carry

    329049Carry New Member

    Thank you for the information. Made a note of it in my growing truck file.
    So far straightening mine has worked Ok, I know that as we use the truck, it will bend again, but for right now, we are enjoying it.


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