Warning re ARDONA stepper method

[C M Smith <cmsmith@domain.elided>]

This is my response to the unlucky 164 owner stuck part way through the 
ARDONA stepper replacement method. The method works well when you are faced 
with doing hundreds of these repairs, the risks of an unlucky break are 
amortized. If you happen to be the unlucky one.. it doesn't work so well. 
there are many things that can go wrong during the ARDONA method which will 
erase any time advantage.

The official factory approved method (not ARDONA's desperate cobble up job) 
involves removing the entire dashboard assembly from the car. This is done 
by unbolting the dash from the firewall by accessing the mounting nuts in 
the false bulkhead area under the hood. It's time consuming but reliable. 
It is unfortunate you might have to do this but the inability to access the 
screws at the base of the windshield isn't a problem once the dash comes out.

  Don't be mislead though, this is a very lengthy procedure involving 
removal of the AC evaporator and a bunch of stuff. A trained and 
experienced mechanic takes 10 to 12 hours to do the steppers by the 
approved method. That's why ARDONA was so desperate to devise a cheaper 
way. Unfortunately, it takes a trained, experienced and LUCKY  mechanic to 
do it the ARDONA way. You are one of the unlucky ones. ARDONA could afford 
to be unlucky every now and again, you are now understanding the costs of 
being THE unlucky owner. My mechanic refused to use the ARDONA method for 
this reason, if it goes wrong the job is twice as long!

Trouble with the design is the entire dashboard is assemble outside the car 
in the factory. Unfortunately, Alfa got so excited about the cost savings 
of this approach they forgot about serviceability once installed. SAAB used 
the same cost saving assembly method but ensured that the top came off the 
dashboard (by inserting screws from below!) and the HVAC controllers could 
be accessed by removing the glovebox (or airbag in later cars).

Alfa deserves criticism for omitting an in car serviceable dash assembly. 
You are now reaping the expenses Alfa saved!

Good Luck

Michael


Michael Smith
Calgary, Alberta
Canada
91 Alfa 164L, White, original owner

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