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A/C Temperature Switch Modification
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Pelican Technical Article:

A/C Temperature Switch Modification

Blair Longhouse

Applicable Models:

Porsche 911 (1977-89)
Porsche 930 Turbo (1977-89)

A/C Temperature Switch Modification

This outlines the modifications I made to the currently available A/C thermostat switch to fit my 1987 911. This the first time (and hopefully only time) I have done this repair and can't comment on whether other model years require similar changes. Don't know if this is what Porsche had in mind for modifications to the switch but it worked for me.

As noted on the Pelican site the original equipment switch is no longer available and the recommended replacement switch (#911-613-121-01) requires "modification" to fit.

Hope this helps, at least you now have an idea of what is required before you take on this task or decide to hand it off to a mechanic.

Blair L

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This picture shows the original (defective) switch on the left
Figure 1

This picture shows the original (defective) switch on the left and new switch on the right. The new switch is approximately 3 mm taller than the original and will not fit into the console as is, the options are to open up the opening in the console or reduce the size of the switch. The other issue is the shaft on the switch is centered on the body but the mounting hole on the console is offset upwards. This means that the 3mm of material must all be removed from one side of the switch and not some from both ends.

The end of the switch where the electrical connections are located is the end that needs to be trimmed back.
Figure 2

The end of the switch where the electrical connections are located is the end that needs to be trimmed back. I began by removing the end of the steel housing by lifting up on the tab; twist it a couple of times and off it comes.

To remove the metal and plastic I started with a metal file but quickly switched to a be
Figure 3

To remove the metal and plastic I started with a metal file but quickly switched to a belt sander to expedite the job, after a few trips between the basement and the garage the switch fit into the console with just a little sanding required to the mount hole in the console to allow the shaft to fit through cleanly.

Use the material around the lower electrical connection (arrow) to gauge your progress,
Figure 4

Use the material around the lower electrical connection (arrow) to gauge your progress, approximately 1 mm of material remained (do not cut it all away) when the switch fits the console.

Another related tip is to cut off the capillary tube at the base of the old temp switch, do not pull it out of the firewall. Once the new switch is mounted into the console carefully unwind the capillary tube and lay it along-side the end of the old capillary tube. I overlapped the new tube approximately 4 inches to the old tube and then wrapped them with electrical tape. Working from the smugglers box, gently pull on the old capillary tube, the new capillary should be pulled through the firewall attached to the end of the old one. Insert approximately 4 inches of the capillary tube into the evaporator enclosure and you are done.

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Comments and Suggestions:
Gerry Comments: Good article.

However, the switch I received from our host does not append to the housing easily.

This is due to the shorter appending thread length compared to the original part which takes the nut.

The threads should be about 1/8" longer.
March 16, 2016
  Followup from the Pelican Staff: Did you get the switch from Pelican Parts?

Give our parts specialists a call at 1-888-280-7799. They can help you find the right part.
- Nick at Pelican Parts
Joe Comments: Hello Pelican Parts tech support ! I am trying to remove the ac switch that turns on the ac and controls the three fan speeds to cool the cabin. My only huge problem is, that I cannot for the life of me remove each wire connected to the switch. The connectors have a tab the goes thru the male connector and prevents the female connector from being removed simply by tuggin on it ! It is killing me that a 30 min job is taking way over an hour. Any suggestions ? Thx so much, Joe 1982 Porsche 911sc
September 18, 2013
  Followup from the Pelican Staff: If I remember correctly it is a spade style connector. If there is a tab that prevents them the terminal from being pulled straight off. try pressing the tab with a small pick while pulling the terminal off. Once you get it past the hole on the male spade it will come off. - Nick at Pelican Parts  
johnboy Comments: what do i do if rear tail light mounting screws strip or just turn the screw plate the light housing is attached to?? trying to put new rubbers between lens andhousing.
November 4, 2012
  Followup from the Pelican Staff: if the screws are stripped and you cannot get a grip with a screwdriver or vise grip, you will have to drill the screw head off, then remove the lens. Once the lesn is removed, you should be able to grab the screw with vise grips and remove it. - Nick at Pelican Parts  
damian911 Comments: Great tech article, can u add the final electrical connection instructions in the back of the switch please? Its now been two weeks since i remove the wires and not too sure where the solid green and stripped green wiren get reattache in the back of the switch??? thanks for makeing it an easier and faster fix ... damian
July 16, 2011
  Followup from the Pelican Staff: Hi, as stated in the article we aren't 100% sure of the coverage or when changes occured. If you supply your vehicle info, someone might be able to help. - Nick at Pelican Parts  

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