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Lighting and Accessories
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Discussion Starter #1 (Edited)
Hey everybody,

Well this is mainly for the 03-04 manual a/c control guys, but everyone can read it, is it is quite entertaining.

(not really)

Anyway, this is for anyone who's having problems with their manual A/C control unit.

Many will find that the plug receptacle on the control unit melts. Mine eventually melted so badly that the clips holding it to the rest of the unit came off and the plug popped off of the unit. It is normally held on by these clips as well as good old Hyundai white glue stuff, shown in a pic below.

My A/C controls haven't been working properly for some time now. First, my A/C didn't turn on until setting 3 of the fan level. Then, I had to set the fan in between 2 and 3 for it to work. Then setting 4 didn't work, but if I put it between 3 and 4 it would work on 4 level. It was basically messed up.




So if you're having any kind of a problem like this, or if your plug is really melted, I would recommend the following:

take off (mine fell off) the plug receptacle thing on the end of the A/C control. You can see this in the background of the next picture. It should then fall apart because there is a spring underneath it (this is why you can push the knob in) and then the metal disc, which spins and touches contact points to transfer the signal. You can see these raised contact points:



Hold the disc in place where you think it should go. There's tabs on it, so it's not hard to figure it out. If the part that the metal disc sits on comes up, you also have to realign that:



When you get that back on, place the metal disc in place:


As you can see in this picture, of the metal disc and the plastic piece it sits on top of that may of may not fall out for you (it didn't for me) there are tabs that you align to get the disc in the proper position:



Right under the thumb is the tab that is aligned with a notch in the plastic.


Then put it back together, not forgetting the spring, and, holding it together, turn on the car and move the dial to make sure everything's in the right place. If it's not, try it again.

If it is all good, just put a couple of drops of superglue to hold the plug receptacle and the unit together nice and tight, because that Hyundai glue just sucks, and your clips are probably melted. If yours has melted at all, there's a chance that it's not holding the plug as tightly as it should be, and that spring is pushing it away, messing up your functioning of the knob.

It took me a grand total of 4 minutes and fours drops of superglue, and now it works like it's brand new!

PICTURES COURTESY JOVANIE! :)

P.S. When you get it apart, watch out. There's a TON of white gluey stuff which obviously doesn't do a good job of gluing anything. It can get messy at first.

I'll take questions- I'm here to help!
 

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Nice job bro'. I'm not hijacking this thread, just posting a solution for a similar problem I had.

I had a similar problem. The blower worked at all speeds but the A/C compressor started to come on/off (light blinked) at 4th speed. Then started doing that at 3rd speed. When it started doing that at 2nd speed, I checked the wiring diagram and noticed that with the A/C button on and the blower at any speed, a ground signal is fed to the control unit (behind right button). What I did was to ran a supplemental ground to the signal fed to the control unit. Everything went back to normal, cold air at any blower speed. 6 months later and still working.

 

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take off (mine fell off) the plug receptecale thing on the end of the A/C control. There is a spring underneath it (this is why you can push the knob in) and then the metal disc. Hold the disc in place where you think it should go. There's tabs on it, so it's not hard to figure it out. Then put it back together, and, holding it, turn on the car and move the dial to see if everything's in the right place. If it's not, try it again.

I open mine up today.... if I was looking at the correct thing, then there is only ONE way it can go. The disc assembly's hole has to match up with the long part sticking out. I lined them up and put it back together without glueing it and it worked. But then I got the "superb" idea of pushing the dial knob and it got messed up again. I'm still not sure if this will help, but I will glue it tomarrow.

Paul.... does the disc only line up one way? Just want to be sure that I moved what I was supposed to move.
 

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Discussion Starter #7
I think it does. I didn't try other ways, I just got it in there the first way that looked best and it worked.

But yeah, that spring in there will shove the back out and mess it up especially when you press the knob in, so you've got to glue it because that white Hyundai glue doesn't do ****.
 

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Same thing appened to my 04 gt. at first i tried to super glue but that didnt work. so i was so pi**ed off that i just wrapped it very tight with a bunch of electrical tape and it worked beautifully. i guess when i fix my tibby ill use that glue you mentioned. thanks bro!
 

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What do you do if your blower (heat on or a/c on dont matter) doesnt work on settings 3 and 4?

It works fine on 1 and 2 but 3 and 4 is like off?
 

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Discussion Starter #15
Yeah the glue melted on mine after a while too. Fixed it again, worked well for about a month, then I finally just got a new one. My connector is very badly melted.

Ryan, you have this same problem, you can fix it by doing the same thing.
 

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This DIY needs better pics... like where EXACTLY its located...

I read everything and I normally get things because I know my way around the Tib... but this is just not doing it for me...
 

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Discussion Starter #17
What are you talking about man? Undo your center fascia, take out the A/C controls, unplug the connectors and everything. Look at the back of the connector on the "stem" and unclip it, and there's where all of the pics were taken from. I didn't even unclip mine though because the clips melted off and it just eventually popped out and broke completely.
 
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