Originally Posted by Jaime-Corvette

i did everything everyone could ever offer on not just this thread but many others. i decided to bypass the center connector from the hvac and run the colored tubes through with 7/64 vacuum tube all the way connected with the colored tubes that used to be on the green silicon connector. i cut the colored tubes from the green silicon connector. many people did it this method and so did i. i finally finished this project and it took me from 11am till 8pm with breaks and store runs.

in the end. it is a total disappointment and im very very very pissed off with what had just happened.

the whole thing acts up the same. i even let it run for 15 minutes and still no front facing ac, just defroster and legs.

i decided to give up on it. i honestly dont think there is any way my 95 will ever have an ac again. but thank you to all that have helped.

Originally Posted by Jaime-Corvette

I'm not sure exactly which hose is which on the car. But taking off both fuel rail covers, all the hoses are in good condition and none are ripped or unconnected. I did change the vacuum check valve but that was the only thing that was actually broken plastic. Other than that it's all good down there.

Originally Posted by Clock-work

Is the cruise control working? I'm assuming cruise was pretty much standard on most 'Vettes and if yours is equipped there's an excellent place to check for system vacuum. The cruise servo has two hoses connected to nipples on its side. There's a larger and smaller hose. The smaller one has the vacuum that's used for the HVAC system. It also connects to the spherical vacuum reservoir that's present (in my '96 anyway) in front of the left tire in the bodywork. A very thin nylon tube of maybe 4mm diameter runs around connecting all the key vacuum system parts together and lives in the wiring harness that passes by the left wheel area. It also snakes its way across the firewall for a short run to the right-hand side of the engine. You'll see it if you poke around a little. The end of this nylon tube plugs into a rubber fitting that is connected to a vacuum nipple on the passenger side of the intake manifold. I'm pretty sure your '95 and my '96 LT4 are similar in how the vacuum system componentry is situated. Next time you fire it up check for a strong vacuum at the cruise servo. Check both hoses if uncertain but one should be sucking correctly.

Originally Posted by Dad3Sons

Hey Corvette Forum -

Cliff Harris pointed me to this thread. Thanks to all who posted their experiences and advice. I bought my 96 Base Coupe from Wathen1955 last March. He took great care of it and told me about the slow action of the A/C programmer/controller. I decided to tackle the repair this weekend and felt well prepared.

My experience was good, although I have a new appreciation for the term "Corvette Yoga". The complete project took me about 5 hours, including prep work like removing the driver's seat and roof and the dash under cover.

Removing the A/C controller module was a challenge. The one 7mm screw that holds it in is easy to remove. The limiting factor was the shortness of the colored vacuum lines from the module to the servos. Don't bother trying to unplug the electrical - it has plenty of slack and will allow the module to drop all the way to the floor. After re-reading this thread, I decided just to clip the colored vacuum lines as close to the plug as I could. Since the plug is the problem anyway, vacuum lines can be easily spliced.

Once I cut the colored vacuum lines, the module dropped out readily. Getting the module on the bench, pulling the push-on nut, the problem was immediately obvious. The #4 nipple - vacuum source - was so poorly manufactured, there was basically no hole there. I trimmed about 1mm off the nipple, then another, then cut down to the bulge where it seals against the plug. It was almost completely closed up.

I just decided to bypass the whole connection assembly and use 5/32" rubber vacuum line. The colored nylon lines push into the rubber pretty snugly. Just spritz on some soapy water and insert a 1/4" or so.

I bought 6' of rubber line for about $2. I cut 12" sections and marked the line with tape for each color. Install the lines on the servo feeds and vacuum source under the dash first. That involves some "yoga". I held the servo feeds with a pair of flat pliers and twisted the rubber onto the colored nylon about 1/4".

In the module, remove the nipple array at the corner, cut the colored lines at the round array, and drill out 5 of the holes to 1/4". Then inside the car just feed each line into a hole in the module box and connect to the corresponding color inside the module. Then just reinstall the box above the accelerator.

My AC controller works flawlessly! It will respond to any change command in 2-3 seconds.

Thanks again for all your experience. This was the most difficult car repair I've attempted in 30 years, and it went really well. [ATTACH]Attachment 47866409[/ATTACH]

Originally Posted by drcook

what size tubes did you buy diameter wise

Originally Posted by Whaleman

Please allow me to ask a dumb question. I have a 96. It is the manual HVAC control. Do I have this controller with the weak rubber tips. My system works fine. Thank You, Dan

Originally Posted by drcook

what size tubes did you buy diameter wise

Originally Posted by Finalatom

How did you connect the 1/8 tubing?

Originally Posted by drcook

what size tubes did you buy diameter wise