Heater Core replacement.....Tips? Suggestions? Instructions?

[bda1855]

Like the title says...truck is down for a while cuase im clearing the whole interior for RAAM Mat and stereo... thought i would tackle the 3 year old busted heater core now instead of later...

anyone got any tips, advice or maybe a FOrd CD how to?

i know the dash has to come all but out... but im wondering HOW THE HELL i do that correctly?

should be fun... i started yesterday... put the truck in the car port and start to strip the interior....

im hoping to have the truck back up by thanksgiving....

 

[RIDE THE]

Once the dash is out the heater core is gravy. The cover comes off the top of the Heater box and then you just pull out the core and put in the new one.

I'll post up the shop manual pages for the dash R&R.

 

[RIDE THE]

Damn, this took awhile to copy.


INSTRUMENT PANEL REMOVAL

1. If equipped with power seats, move the seat fully rearward.
2. If equipped with adjustable pedal system, move the pedal to the full forward position.
3. If equipped with a manual transmission, place the transmission in second gear.
4. Remove the passenger air bag module.
5. Remove the driver air bag module. (Leave it on)

6. Position the battery junction box (BJB) aside.
Release the mounting tabs.

7. Remove the bulkhead electrical connectors from inside the engine compartment.
1 Loosen the bolts.
2 Disconnect the bulkhead electrical connectors.

8. Remove the bulkhead electrical connector insulator.

9. Unclip the bulkhead electrical connectors from the dash panel.

10. If equipped, remove the valance panel.

11. Disconnect the restraint control module (RCM) electrical connector.
1 Release the locking tab.
2 Disconnect the RCM electrical connector.

12. Disconnect the electronic blend door actuator electrical connector.
Release the wiring harness locators.

13. Disconnect the climate control head vacuum harness connector.

14. Remove the LH and RH front door scuff plates.

15. Position the LH and RH door weatherstrip seals aside.

16. Remove the LH and RH A-pillar lower trim panels.

17. If equipped, remove the alternative fuel control module (AFCM).
1 Disconnect the electrical connector.
2 NOTE: The AFCM is attached with Velcro (R).

Remove the AFCM from the vehicle by pulling gently down and to the right.
(We do not have this module)

18. Remove the LH and RH A-pillar passenger assist handles.
Remove the four covers and the nuts.

19. CAUTION: Inspect the passenger assist handle brackets for damage. Replace the brackets as required. Remove the LH and RH windshield side garnish mouldings.

20. Disconnect the brake pedal position (BPP) switch electrical connector.
Release the wiring harness locators.

21. If equipped, disconnect the adjustable pedal motor electrical connector.
(unless you installed it, We don't have it)

22. If equipped, disconnect the adjustable pedal motor harness electrical connector.
(unless you installed it, We don't have it)

23. If equipped, disconnect the clutch pedal position (CPP) switch.
(unless you installed it, We don't have it)

24. Remove the (A) audio unit ground and the (B) GEM/CTM ground bolts.

25. Disconnect the LH instrument panel main wiring harness connectors.
Release all the main wiring harness locators.

26. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the nuts.
2 Remove the instrument panel steering column opening cover reinforcement.

27. Disconnect the clockspring electrical connectors and the anti-theft sensor electrical connector.

28. Disconnect the remaining electrical connectors on the steering column.

29. If equipped, disconnect the transmission range indicator from the steering column.
1 Remove the bolt.
2 Disconnect the cable.

30. Lower the steering column.
1 Remove the nuts.
2 Lower the steering column.

31. Remove the instrument panel bolts through the steering column opening.

32. Remove the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.

33. Disconnect the inertia fuel shutoff switch electrical connector.

34. Remove the RH ground bolts.

35. Disconnect the RH instrument panel main harness connectors.
Release all the wiring harness locators from the cowl side panel.

36.Disconnect the climate control wiring harness connector.

37. If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
(Unless you installed it, we don't have it)

38. Remove the audio unit. (Leave the radio in the dash)

39. Remove the antenna lead-in cable from the instrument panel.
1 Disconnect the three cable locators from the lower instrument panel channel.
2 Remove the antenna lead-in cable from the instrument panel.
(You do not need to remove the entire antenna cable, just unplug it at the bottom of the dash by the passengers kick panel)

40. Remove the glove compartment and the surfboard panel above the passengers airbag module.

41. Remove the instrument panel bolts through the passenger side air bag module opening.

42. Remove the instrument panel bolt on the relay bracket through the surfboard panel opening.

43. Remove the instrument panel reinforcement bolt below the LH corner of the glove compartment.

44. NOTE: Position the carpet aside. Loosen the instrument panel floor brace.
1 Remove the upper instrument panel floor brace bolt.
2 Loosen the instrument panel brace bolts and nut.

45. Remove the RH instrument panel cowl side nut.

46. Remove the LH instrument panel cowl side nut.

47. Remove the instrument panel cowl top bolts.
1 Remove the covers.
2 Remove the bolts.

NOTE: This step will require an assistant. Remove the instrument panel.

Installation opposite of removal.

If you need any help just PM me.

 

[Charlie41]

Holly crap!!!!!!! I'll freeze first!

Charlie

 

[bgstew6]

bout a 4hour job if your good LOL

it aint fun

 

[SWThomas]

Awesome post RIDE THE!!! I'm saving that in my tech notes.

 

[bda1855]

Holly crap!!!!!!! I'll freeze first!

Charlie

HAHAHA already did that for two winters! Last winter i drove home from Dantes Shop 2 hour drive... it was 32 degrees out....

i froze my ass off!

The interior is completly gutted (save for the dash).... i am going to run all new wiring for the Amps/SUB/and CD changer so i need to be int eh dash anyhow...

Thanks RIDETHE... this will come in very very very very handy!!!! not looking forward to it but i need to do it...trying to get the truck in TIP TOP shape... should be close after all this...

 

[venomous]

Just be careful with the metal brackets behing the dash....the metal framing is very sharp in places....had cuts all over my hands and almost lost a finger when I did my buddies 2000 L. Same thing with my old fox GT. Ford must design this things so they can make some $$$ off those who have no mechanical skill.

 

[RIDE THE]

not looking forward to it but i need to do it...

Not a hard job at all. I know yours is stripped but I normally take out the seats and the console to make it easier to work and less chance of damage. Like Stew said. If you know what your doing and have air tools it can be done in 2 to 4 hours. If your in no rush it will be easy. Just take your time.

I just sucks that the Ford designers couldn't have made it easier to get the core out of the case. The older F series and Broncos would almost poop out the core behind the glove box.:bash:

 

[bgstew6]

they would....it was an easy R&R LOL...not anymore

 

[bda1855]

Not a hard job at all. I know yours is stripped but I normally take out the seats and the console to make it easier to work and less chance of damage. Like Stew said. If you know what your doing and have air tools it can be done in 2 to 4 hours. If your in no rush it will be easy. Just take your time.

I just sucks that the Ford designers couldn't have made it easier to get the core out of the case. The older F series and Broncos would almost poop out the core behind the glove box.:bash:

Word... i got air tools and an electric impact... i will start on this tonight.. hopefully i can be done by thursday night (still waiting on the core to arrive from Fordparts.com)

 

[bda1855]

WOW!!!!

Sid should make the procedure above a How Too...

this made it SO SO easy... took me about 2 hours to get the heater core out... and i was using hand tools cause the line from my compressor to my hose reel sprang a leak (GRRRRR)...

anyhow.. for a first time NOOB... this made it super easy, and saved me the headache of trying to "Figure out" which screws come out and which ones can stay (like the gauge cluster surround, radio surround etc...

BIG HUGE THANKS to Eric for the help on this.. my fiance thanks you big time! (she gets cold...)

thanks for the tip about the foam also...

im gonna slap it all together tonight and then start the RAAM Audio Mat tomorrow AM...

 

[RIDE THE]

Glad I could help. :thumbsup: