The heat selector knob on my '03 Cavalier no longer works in the far left or far right positions. As a result, AC and heat only come out of the main dash vents and so I have no defrost or floor air. When I do try to turn the knob to the left or right, it snaps back to the middle.

A while back I found someone on another website who had my same problem, and they even listed the part number they replaced. Apparently there is a kink in the cable that connects to the heat selector knob.

Me being an idiot I either wrote it down and lost it or didn't write it down. I need to know the part number for that cable which is kinked.

Thanks in advance.

Bulletin 03-01-38-005A covers various HVAC concerns on 2003-04 Chevrolet Cavalier and Pontiac Sunfire related to mode and temperature control cables.

Be sure to refer to the bulletin for details. Here are some highlights.

Because symptoms show up as a control knob that is difficult to move, blame is often placed wrongly on the control head. The control head has not been identified as a cause of effort concerns, although the head may become damaged by forcing a knob to overcome an operating condition elsewhere.

TIP: Be sure the cable mounting tabs on the control head are intact.

Cable Conditions
The bulletin points out that a cable may bind, or may become kinked, due to:
- Improper cable routing -- Be sure routing does not cause cable housing or cam interference when the control head knob is operated.
- Improper cable clip positioning -- May have been improperly installed at assembly, or may have pulled off by forcing the control head.
- Cable interference with wiring -- Tie back wiring as necessary.
- Stuck or binding valve -- The defrost valve arm may drop off the edge of the surface and become stuck. The bulletin details how to grind the area. Foam or adhesive may interfere with operaton of defrost and mode valves (fig. 16). The bulletin explains how to trim the material to allow free operation.

Repair Tips
Here are some general tips.
- For diffiucult mode valve operation, where the valve is not stuck, check the mode cable housing for interference with the cam. The cable can interfere with the cam during rotation (fig. 17), causing a condition of low effort, high effort then low effort again.
- If a cable is kinked or stretched, replace it.
- Cables don’t have to be replaced in pairs.
- If routing or clip position was incorrect, be sure to fully function test after making repairs.
- If a cable and clips are not damaged, the cable may be re-used.

TIP: Part number 89018237 (seal kit) is NOT required when replacing a cable. The parts book will be updated on April 1.

part number for the cable # 89018243


If at first you don't succeed, destroy all evidence you tried!

Well, I guess that's about as complete of an answer as I can get. I'll refer this page to my friend who actually knows a lot about cars and see what he can glean from it. I tried searching the forums before posting, but didnt find this topic.

Thanks!