Heater Core Swap with Pics
Ok, here goes. Please note that some screws my be missing in the pictures, I occasionally got ahead of myself. I may try to go into paint or similar later and doctor some of the pics to show exactly what is being talked about. Any damages caused by this are not the fault of FEOA.NET or myself. If this should be moved to a new thread, let me know, and as for sources, THIS THREAD HAS BEEN MY SOURCE, I just added pics and a few tips. Sorry for lack of pics all the way to the end but the last is a breeze anyways.
The tools needed for this job are very minimal. You need:
T20 Torx bit
Phillips screwdriver
Flat screwdriver (for prying only)
10 mm wrench
10 mm socked
12 mm socket
ratchet((s) if using more than one size like in my cheap tool set)
ratchet extension(s)
pliers
Ford radio removal tool (or a cut up hanger)
ALSO REALLY HELPFUL
flexible bit driver (helps for the window mold piece)
camera
sharpy
small ziplock baggies
These are to store screws and bolts and write on them what they go to. It really really helps and saves time even though you feel like your wasting time.
Step one: Assemble all tools needed.
Step two: Disconnect battery cable.
Step three: Disconnect Speedo cable (better now than later and it gives you a chance to wash up) Do this by removing the C-clip that holds it in located just under the fuel filter in the engine compartment which next to th e break booster. This will give you the slack needed to remove the instrument cluster. Also disconnect the heater core and plug the hoses in whatever fashion you desire, there are many ways described previously in this thread.
Step four: Remove radio using the tool or hanger. It should slide out with a bit of jiggling, some are a bit sticky if they have the rubber piece at the back to hold it steady. Carefully unhook all wires from the radio and set aside. Also remove the ashtray.
Step five: Remove the glove box. You will find two torx at the bottom, one on each side. Once these are taken out it just pivots on two nubs and can be removed easily.
Step six: Remove the side panel on the passenger side by prying it out with screwdriver. Once this is removed you will see a torx. Remove it, I found using a torx bit with a 1/4 inch drive and 1/4 inch socked to put the bit in got it since my bit tool was too long, and the others that are under the dash and remove the panel that is to the right of the glove box. It will also have a snap in piece so it will give some resistance.
Step seven: On the drivers side remove the same panel and take out the torx there as well as the ones underneath the dash panel. There will also be one torx on the right top of the panel underneath a pop-out. Just use your screwdriver to release it and remove the screw. This will have snap-ins as well and so will give some resistance. Don't pull to hard, you have to remove the dimmer wire from it before removing it completely.
Step eight: Remove the screws holding in the shifter/parking break piece. There will be six of them, 2 in front, 2 in the middle, and two in the back, then slide the back piece back a couple of inches and remove the shifter cover.
Step nine: Unhook the cable from the white gears on the black box that lead to the temperature control unit. They are very easy to do at this point and if you try and remove them from the unit itself without doing this, you will damage the cable. Once they have popped off the quick-disconnect tabs, you must also unclip them from the metal braces, make marks on them if you wish so you can position them the same way later.
Step ten: Remove the 4 torx holding the center dash on, two on the left, one on the right where the glove box shuts, and one in where the ash tray is. Slowly pull out the whole thing and disconnect the wires and vacuum hoses from the temperature control unit and make sure not to kink the cable or pull to hard. Once that is out set aside.
Step eleven: Remove the cover from the steering column by removing the screws and then unsnapping the cover from itself. Set aside and locate the four bolts that hold the steering column up. Undo using a 12 mm socket and rachet with extension. Gently lower column to the seat.
Step twelve: Take out the 8 torx that hold the black part of the dash on. 3 on the inside, 5 underneath, with 3 on the left and 2 on the right. Remove this panel making sure to unhook the wires clusters on each side and set aside.
Step thirteen: Undo the 4 torx holding the gauge cluster in, the black, not the gold ones. Slowly pull the cluster out making sure not to pull to hard, if needed have someone press the speedo cable into the firewall from the other side to avoid undue stress. Remove the three wire clusters and the speedo by compressing the black thing and pulling out, can be tricky at first but once you get it the first time it is easy. Set aside
Step fourteen: Remove the trim panel right under the window by undoing the one torx found in the center. This is best done with a flexible bit driver but can also be done with just a T20 torx that you have been using the whole time and a pair of pliers. pry it out, it has many snaps that hold it in so be careful and try to pry evenly. Once removed there are 3 more bolts. They are 10mm and are best gotten with an open ended wrench, it just takes a bit and is slow going. Also, it is a great idea to tie something to the other end of the wrench to avoid dropping it in the dash, saved for sure. Remove those and set the trim aside.
Step fifteen: Remove the four bolts holding the lower dash to the floor board, and the four bolts, two on either side of the dash that hold it to the fire wall. At this point your dash is free of the car except for many wires that need to be unplugged. You can pivot it toward you and then look into the widow from the outsisde to make sure you are getting all the wires. Also make sure you get the vents unhooked on both sides, they are just small connector peices that snap off. DO NOT FORGET TO PUT THESE BACK OR YOU WILL NO AIR OR HEAT COMING OUT OF YOUR SIDE VENTNS. Once it is unhooked, remove dash and set aside.
Step sixteen: The black box in the center is held on by three torx, remove them and pull the unit out. Remove the three screws that hold in the heater core, and put in a new one.
Step seventeen: Reverse the whole process.