How to fix a broken heater flap on a Peugeot 407.
This problem seems to be very common on the 407, its more a question of when it will break rather than if. Dealers will want to remove the dash and most mechanics will not want to do this job. However if you set a few hours aside its something that can be done DIY. A bit messy and fiddly but it is a repair that i have now done on several 407 and it has continued to work well.
A link to the STL files so that you can 3D print the reinforcements
https://www.prusaprinters.org/prints/108488-peugeot-407-heater-flap-reinforcement
3D print files for the hacksaw blade holder
https://www.prusaprinters.org/prints/108491-hacksaw-blade-holder
Facebook page for this channel if you have any questions
https://www.facebook.com/PC2CV
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I would take the motors off completely and just manually adjust the flaps with screw driver in "winter position" and "summer position" (hot/cold). You can still adjust the direct of the airflow and fan speed to keep the cabin comfy enough for different weathers. If you feel too cold in the summer, just turn fan off or adjust the flaps slightly to warmer with screwdriver. The motors will just break the flaps again and again, because it is a bad design ac-unit (worst I have ever seen). There is no cure to this problem called PSA.
What about LHD Euro version 407?
Unsurprisingly, Peugeot decided to replace the entire heater box with a redesigned unit from a different manufacturer in 2008.
The heat is too big for glue gun. I fixed my flaps from above without cutting. The blue flaps was broken.
Great job.
As always, thanks for sharing your tutorials !!
Nice job!!! That would be an expensive repair. Thanks 4 sharing.
That was some Serious Wreching…
Didn't know you have a 3D printer nowadays.
Nice!