another update, I took the motor off the side of the flaps and the motor spindle seems to be nice and tight.
The small plastic drive connection between the motor and flaps also seems to be pretty secure but when mated back together there seems to be some play somewhere. I took the plastic drive off the flaps and placed it onto the motor drive, there is no apparent play at this point.
Running out of time I have put it all back together, and of course its behaving just as before. I have noticed that the flaps move to different positions, so if I switch between recirc and normal a few times it is possible to get the flaps to be open enough to let air flow through.
Found a thread on audiworld with someone having the same problem, and there is a video showing the flaps and mine move nowhere near this amount.
http://forums.audiworld.com/showthread.php?t=2813312
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Manny
2004 A4 1.8T Sport Cabriolet, 89K Miles
Past
2004 D3 A8 3.7 Quattro, Xenon, Bose, Blinds, Solar Sunroof, TV, ACC, phone and almost every option. 168K miles rising slowly
with retrofit AMI and DVB-T in place of Analogue
2003 Volvo S60 D5 SE Manual, 197K miles.
2001 D2 A8 3.7 QS, Bi-Xenon, Bose, Blinds, Electric Everything, retrofitted RNS-D, 191K Miles
Last edited by mannyo; 29th January 2012 at 01:02 PM.
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