How to repair a rusted heater control cable W/Pics

[Shealey]

I asked about how to remove and replace the cable section of the duel fuction fan switch and heater control. Mine rotated right to left working the fan, but the cable was rusted solid about midway. I tried PB Blaster shooting the cable periodically over the last couple weeks. It didn't help. So I took the suggestion offered here on the board. It was suggested I could remove the sheathing and replace it with one from a cheap choke cable.

Well I happen to have a brand new cheap choke cable. The one I ordered to replace my frozen choke cable is not an acceptible match for the stock style knobs.And besides, I got my stock cable to free up! Woo Hoo!

So, I used my die grinder and carefully cut the outer sheathing about 4" in on the outer sheathing. I didn't cut all the way through but close. With a pair of pliers I twisted the sheathing and cracked it at the cut. After I separated the sheathing at the rusted section I was able to move the cable fine. So I simply un-threaded the sheathing from the end of the switch.

Thanks for the tip. Here's a couple of photos showing the progress.

Here's my combo switch:

Here's the outer sheathing cut off at the rusted section:

Here's the outer sheathing unthreaded from the switch body ready for the new sheathing: