Anyone who has tackled heater core replacement will tell you they'd rather have an all-nighttime root canal than take to perform this dreaded chore. Heater core leakage begins with the subtle olfactory property of antifreeze and evolves into a small wet spot on the driveway. Past the time you have coolant on the pavement there is no manner effectually information technology. You're going to have to replace the heater core or load up on Stop Leak.
Back in the day, on older Ford F-Series trucks, heater core placement involved going upwards nether the dashboard and removing the heating and air-conditioning unit. In the '70s, Ford began installing HVAC systems before dashboards were bolted into the vehicle. Dashboards, which were preassembled on rotisseries, were installed in the vehicle via an installation fixture and a couple of assembly workers. This approach made vehicle assembly easier and quicker. Yet, it also meant extensive labor for the technician faced with heater core and/or air-conditioning evaporator replacement.
Nosotros're working with a '98 Ford F-150 with nearly 267,000 miles on the odometer after 18 years of service. That's pretty good, considering most F-Series trucks have experienced chronic heater cadre failure before in their service lives. Heater cores have always been a weak spot in Ford vehicles for diverse reasons, including excessive cooling organisation pressure level and volume, which has been improved in product via the utilize of heater hose restrictors between the engine and heater cadre.
Heater core replacement in the F-Series, Expedition, and Lincoln Navigator involves removal of the dashboard to where it can exist disconnected and swung away from the HVAC unit bolted to the firewall. Some technicians have managed to unbolt the dashboard and swing it out far enough to gain access to the HVAC unit. Others disconnect the steering column and remove the entire dashboard for easier admission. It is suggested you use 18-carat Motorcraft parts where possible, which are available from Stone Automobile, in your heater core replacement, including cooling system hoses, which accept the manufactory-mode quick connections at the firewall. Motorcraft heater hoses also take the catamenia-restrictor in the "in" hose designed to prevent heater cadre failure from pressure and excessive flow. Not all aftermarket replacement heater hoses accept this restrictor. Heater hose quick-connects are annihilation just "quick" disconnect. You lot're going to demand the quick-disconnect tool available at any auto parts store or Meridian Racing Equipment. If you're replacing the heater hoses, you can cutting the quick-connect tabs and pull the connectors.
Although we're working with a '97-to-'03-generation F-Serial truck, bones principles of replacement are the same from for '97-to-'17 models. Let'southward become started.
In the interest of rubber, the offset order of business is to disconnect the bombardment before performing any disassembly. Bleed the cooling organisation and properly dispose of any coolant. Seat and jack bracket removal is suggested for improved access to the dashboard and HVAC associates. A Torx wrench is required to remove seats and seatbelts. Information technology is a good thought to have the cooling system flushed before heater cadre replacement.
Rocker sill molding removal is easy. Information technology pops in and out with no tools required. Kick panel removal, which pops in and out, is next to proceeds access to wiring and modules, which have to be disconnected from the dashboard.
We removed the A-pillar console and handhold for improved access and photographic purposes, but you won't have to practice this.
This flexible nuance cap on pinnacle has to exist removed carefully. If you lot become aggressive with this slice, information technology will crack—specially when you consider how old these trucks are today. Plastic parts become very brittle and tin can crack over time. Retaining tabs were originally coated with white grease for like shooting fish in a barrel installation and removal.
Airbag removal is performed with the removal of three bolts (2 bottom and one top), using a 10mm socket. We have removed the glove compartment door for photo purposes, but you lot won't have to. Tabs at the top of the glovebox door can be advisedly bent to each side, which enables you to lower the door far plenty to admission airbag bolts and dash screws.
With the three bolts removed acme and bottom, the airbag associates comes right out. A 2-pin plug connects the airbag. Nosotros circumspection you must be very careful with airbags during service. Store them facedown in a protected location. Even static electricity tin cause an airbag to fire.
Airbag bolt locations on '97-to-'03 F-150s are in three places (arrows).
Passenger-side airbag looks like this from behind. At that place's a two-pivot connector tied to the canister within the module. Exercise farthermost caution with airbags: store them on their faces, away from people, to minimize the risk of accidental deployment.
We're dropping the steering column for ease of admission. The steering cavalcade cover pops out without tools.
The bezel higher up the instrument cluster is attached with three screws using a 7mm socket. Once these screws are removed, the bezel pops right out.
You will find the dashboard is tied to the trunk via seemingly dozens of these sheetmetal screws (dozens!), which are removed with a 7mm socket. Follow these screws effectually the perimeter of the dashboard. They secure the dashboard to the body. The F-150 dashboard consists of the shell you see, backed by a plastic inner frame/ductwork assembly tied to a steel framework at the cowl. Gold cad-plated dash screws are coarse thread for threading into plastic. Black or natural cad-plated fine-thread screws are located at copper-plated (metal) inserts.
The musical instrument cluster is removed for improved access. Some technicians remove the unabridged dashboard to make it easier to get to the HVAC assembly, but you don't take to exercise that. The objective is to remove enough of the perimeter screws so you lot tin can swing the dashboard out of the way. Be very careful with the main wiring loom and its connectors.
The steering column is secured with four flange basics. This removable framework is office of the dash construction and is removed as shown to drib the steering column.
In that location are four steering column back up studs. This is an integral part of the collapsible steering column.
The dash pad "chimera" is removed next. Although this looks like a padded dash, it is petty more a removable shell. Apply a 7mm socket to remove these black cad screws.
Disconnect the dashboard from this cluster of harnesses and modules behind the correct-paw kick panel.
One time the dashboard has been moved out of the mode, heater core admission becomes like shooting fish in a barrel. A series of screws secure the top of the HVAC plenum, which is removed for heater core and air-conditioning evaporator admission. You volition demand a 10mm socket for this purpose.
While yous're performing heater core replacement, it is a skilful idea to bank check blower motor and variable resistor status. Both are easy to admission with the dashboard installed, which means you don't have to replace them at this time. We've opted for a Motorcraft heater core. However, the mill estrus blend door has a weak spot at its pivot and should be replaced. The pin bespeak at the alloy door actuator tends to crack and break, which is why we're suggesting the Dorman rut blend door kit (#902220 or #902207) for your F-150 heater core service. The aluminum pivot on the Dorman replacement is solid and volition not fail. It is also suggested you replace the blend door actuator.
The variable resistor package is what affects fan speed, not the fan switch. Fan power is routed through this resistor package to control fan speed.
We've chosen the Motorcraft heater core mostly for reasons of guaranteed fitment. The aftermarket also offers replacement heater cores for F-150s.
The original factory heater blend door assembly, which pops out without tools, is removed and replaced with the improved Dorman alloy door assembly.
The installed Motorcraft heater core is fitted with new foam around its perimeter. The arrow indicates where the heater blend door splines into the electric actuator below. Information technology is incommunicable to install the blend door any manner but the correct way. The HVAC cap is reinstalled using a 10mm socket.
The new Dorman heater blend door is installed as shown. Reinstall the HVAC cap and dashboard/steering column.
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