Anyone who has actually tackled heater core replacement will certainly tell girlfriend they’d rather have actually an all-night source canal than have to perform this dreaded task. Heater main point leakage starts with the subtle aroma of antifreeze and also evolves into a little wet spot on the driveway. By the time you have actually coolant on the pavement over there is no method around it. You’re walking to need to replace the heater core or load up on protect against Leak.

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Back in the day, on older Ford F-Series trucks, heater main point placement associated going increase under the dashboard and also removing the heating and also air-conditioning unit. In the ’70s, Ford started installing HVAC systems before dashboards were bolted into the vehicle. Dashboards, which were preassembled top top rotisseries, were set up in the automobile via an surroundings fixture and also a couple of assembly workers. This method made vehicle assembly easier and also quicker. However, it additionally meant comprehensive labor because that the technician faced with heater core and/or air-conditioning evaporator replacement.


We’re working v a ’98 Ford F-150 with almost 267,000 mile on the odometer ~ 18 years of service. That’s pretty good, considering most F-Series trucks have actually experienced chronic heater main point failure earlier in their service lives. Heater cores have always been a weak clues in Ford vehicles for various reasons, including excessive cooling mechanism pressure and also volume, which has been boosted in manufacturing via the use of heater hose restrictors between the engine and heater core.


Heater core replacement in the F-Series, Expedition, and Lincoln Navigator involves removal the the dashboard to where it can be disconnected and swung far from the HVAC unit bolted to the firewall. Some technicians have managed to unbolt the dashboard and also swing it the end far enough to gain accessibility to the HVAC unit. Rather disconnect the steering column and also remove the whole dashboard for easier access. The is said you use genuine Motorcraft components where possible, i m sorry are accessible from rock Auto, in her heater main point replacement, consisting of cooling device hoses, which have actually the factory-style quick connections at the firewall. Motorcraft heater hoses additionally have the flow-restrictor in the “in” hose designed to prevent heater core failure native pressure and also excessive flow. Not all aftermarket replacement heater hoses have this restrictor. Heater water tap quick-connects are anything but “quick” disconnect. You’re walking to require the quick-disconnect tool obtainable at any kind of auto components store or Summit gyeongju Equipment. If you’re instead of the heater hoses, you can reduced the quick-connect tabs and pull the connectors.


Although we’re working v a ’97-to-’03-generation F-Series truck, basic principles of replacement room the very same from because that ’97-to-’17 models. Let’s acquire started.


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See all 27 photos
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See all 27 photosIn the interest of safety, the very first order of company is come disconnect the battery prior to performing any kind of disassembly. Drainpipe the cooling system and properly dispose of any kind of coolant. Seat and jack bracket remove is said for improved accessibility to the dashboard and HVAC assembly. A Torx wrench is compelled to remove seats and also seatbelts. It is a an excellent idea to have the cooling mechanism flushed before heater main point replacement.
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See all 27 photosRocker sill molding removal is easy. That pops in and also out v no tools required. Kick panel removal, which pops in and out, is beside gain accessibility to wiring and modules, which have to be disconnected from the dashboard.
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See all 27 photosWe eliminated the A-pillar panel and handhold for improved access and photographic purposes, however you won’t need to do this.
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See all 27 photosThis functional dash cap on top has to be gotten rid of carefully. If you get aggressive with this piece, it will certainly crack—especially when you take into consideration how old these trucks room today. Plastic parts become an extremely brittle and can crack over time. Retaining tabs were originally coated v white grease for simple installation and removal.
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See every 27 photosAirbag removal is performed through the remove of three bolts (two bottom and one top), utilizing a 10mm socket. We have actually removed the glove compartment door for photo purposes, but you won’t have actually to. Tabs in ~ the top of the glovebox door can be carefully bent to every side, which permits you to reduced the door far enough to access airbag bolts and dash screws.
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See all 27 photosWith the three bolts removed top and bottom, the airbag assembly comes best out. A two-pin plug connect the airbag. We caution you must be really careful with airbags throughout service. Keep them facedown in a protected location. Also static power can reason an airbag to fire.
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See all 27 photosAirbag bolt areas on ’97-to-’03 F-150s space in three locations (arrows).
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See all 27 photosPassenger-side airbag looks like this native behind. There’s a two-pin connector tied come the canister inside the module. Exercise excessive caution with airbags: save them on your faces, far from people, to minimize the hazard of inadvertently deployment.
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See all 27 photosWe’re dropping the steering pillar for lull of access. The steering obelisk cover pops out without tools.
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See every 27 photosThe bezel above the instrument cluster is enclosed with 3 screws making use of a 7mm socket. As soon as these screws are removed, the bezel pops best out.
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See all 27 photosYou will find the dashboard is tied to the body via seemingly dozens of this sheetmetal screws (dozens!), i m sorry are removed with a 7mm socket. Follow this screws approximately the perimeter the the dashboard. Castle secure the dashboard come the body. The F-150 dashboard consists of the covering you see, donate by a plastic within frame/ductwork assembly tied to a steel framework at the cowl. Yellow cad-plated dash screws space coarse thread because that threading right into plastic. Black or herbal cad-plated fine-thread screws are situated at copper-plated (metal) inserts.
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See every 27 photosThe instrument cluster is eliminated for improved access. Part technicians eliminate the whole dashboard to do it less complicated to acquire to the HVAC assembly, however you don’t have to do that. The target is to remove enough of the perimeter screws therefore you can swing the dashboard the end of the way. Be an extremely careful with the key wiring loom and also its connectors.
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See every 27 photosThe steering column is secured with 4 flange nuts. This removable structure is component of the dash structure and is removed as shown to autumn the steering column.
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See every 27 photosThere are 4 steering tower support studs. This is one integral component of the collapsible steering column.
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See all 27 photosThe dash pad “bubble” is eliminated next. Although this looks favor a padded dash, the is little much more than a removable shell. Usage a 7mm socket to remove these black color cad screws.
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See every 27 photosDisconnect the dashboard indigenous this cluster of harnesses and modules behind the right-hand kick panel.
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See all 27 photosOnce the dashboard has actually been moved out of the way, heater core accessibility becomes easy. A collection of screws secure the optimal of the HVAC plenum, i m sorry is removed for heater core and also air-conditioning evaporator access. You will require a 10mm socket for this purpose.
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See all 27 photosWhile she performing heater main point replacement, it is a good idea to examine blower motor and also variable resistor status. Both are basic to accessibility with the dashboard installed, which method you don’t have to replace them at this time. We’ve opted for a Motorcraft heater core. However, the manufacturing facility heat blend door has actually a weak spot at its pivot and also should be replaced. The pivot point at the blend door actuator tends to crack and also break, which is why we’re arguing the Dorman heat blend door kit (#902220 or #902207) for your F-150 heater main point service. The aluminum pivot ~ above the Dorman instead of is solid and will not fail. That is also suggested you replace the mix door actuator.
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See every 27 photosThe variable resistor parcel is what affects fan speed, no the pan switch. Fan power is routed v this resistor parcel to manage fan speed.
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See every 27 photosWe’ve favored the Motorcraft heater core largely for factors of guarantee fitment. The aftermarket likewise offers replacement heater cores for F-150s.

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See every 27 photosThe original factory heater blend door assembly, i beg your pardon pops out without tools, is removed and also replaced through the improved Dorman mix door assembly.
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See all 27 photosThe mounted Motorcraft heater core is equipment with new foam around its perimeter. The arrowhead indicates whereby the heater mix door splines into the electrical actuator below. The is difficult to download the blend door any method but the ideal way. The HVAC lid is reinstalled utilizing a 10mm socket.
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See every 27 photosThe new Dorman heater blend door is mounted as shown. Reinstall the HVAC cap and also dashboard/steering column.
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