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Okay, I just pulled out the dash control unit on the manual controls. It doesn't look good. Tiny wiring, tiny soldering, lots of miniature switches. Doesn't look like much of a repair option on this thing.
i guess I am looking at temporarily putting a switch coming from the compressor clutch.
Does anyone have one of these 96 panels for sale?
i think the 94-96 are the same, but I dont know for sure.
What about converting this to digital? Is that extremely involved? I rember something about a heat detector on the dash, but is there anything else besides the control unit itself?
You will need the electrical diagnosis service manual for your 96. Power to the clutch goes through the switch on the control head and then through the a/c high pressure switch and the pressure cycling switch. The high pressure switch opens under high gas pressure for safety, the pressure cycling switch turns off the compressor when it isn't needed and back on when needed. Most likely heater control switch is defective because the compressor clutch stays on with the switch , "off". With the electrical manual, you could trace from the electrical terminals to the switch. The wire color and terminal numbers are not likely the same as my 87 for which I have a manual.
The switch is the , "off, max, norm, bi-level etc" one.
I'm not sure if your 96 is the same as my 92, but when I got my car I noticed the same thing happening. I have the electronic climate control and had visions of high dollar parts needing replacement. However, I did more searching and found out that there is a relay for the compressor clutch mounted on the inside of the left front wheel well. When I removed the relay to test its continuity, I found the culprit. I guess at some point the relay had gone bad and someone used a wire peircing type crimp connector to bypass the relay. I removed the crimp, taped the wires and replaced the relay ($12 at NAPA). Now everything works fine. I doubt there are 2 idiots out there who would go to such lengths to save $12 dollars, but its worth a look. I don't know if the relay can go bad and "stick" in the closed position, but if so, it would be a whole lot easier to replace (2 machine screws) than working in the dash. Maybe someone else will chime in. Good Luck.