I can cross another item off the list. Since I’ll be hiding the ATC head, I need to relocate the temperature sensor and aspirator somewhere that they can still sample interior air. Since the thermistor is currently mounted directly to the ATC head PCB, I decided to switch to the unit used in most of the modern FCA vehicles. It’s all integrated in one unit and designed to be installed away from the controls. I’m planning on making a mounting boss for it (probably 3D printed) and finding somewhere to put it. I’ll cut vent holes in the surface, epoxy the boss over them, and mount the sensor to it. I’ll need something relatively flat with enough space behind it and that is exposed to cabin air. I’d also like it to be somewhat inconspicuous in case the slots I make in the panel for air to flow through don’t come out the best. The typical spot nowadays is in the knee bolster, so I’ll probably use that if there’s enough room behind it.
Unfortunately the new unit uses a 47k thermistor instead of the 10k in the ATC head. It’s a nice, small, epoxy dipped piece that the sensor is designed around. I was able to find comparable 10k ones, but after doing testing at various temperatures I found that the one used in the head has a very unusual temperature curve that didn’t match anything I could find. So, I desoldered it from the head and carefully rebuilt the sensor with it. It didn’t go in perfectly because it was a bit too large and I didn’t have the exact size wire, but after some careful solder work and some hot glue it should be functional.
Thermistor I removed from the sensor:

Sensor with thermistor from ATC head:


3D model of my mounting boss design:

Unfortunately the new unit uses a 47k thermistor instead of the 10k in the ATC head. It’s a nice, small, epoxy dipped piece that the sensor is designed around. I was able to find comparable 10k ones, but after doing testing at various temperatures I found that the one used in the head has a very unusual temperature curve that didn’t match anything I could find. So, I desoldered it from the head and carefully rebuilt the sensor with it. It didn’t go in perfectly because it was a bit too large and I didn’t have the exact size wire, but after some careful solder work and some hot glue it should be functional.
Thermistor I removed from the sensor:

Sensor with thermistor from ATC head:


3D model of my mounting boss design:
