1997 F150 Heater Core Replacement
Contents
1. hose tool is only needed to reach under the dash overhang while under the hood to release the hoses Be sure to replace the o rings 2 rubber 1 plastic on each hose You just stack them inside the hose tip rubber plastic rubber Then you snap into place the plastic clip making sure the tabs fit into the openings on the side of the heater hose fitting The plastic ends stick out of the end of the hose I snapped it in and didn t notice the little tabs weren t lined up with the slots Luckily I got it off and got them aligned correctly The hoses just snap back on the heater core you ll feel them click into place Remove the A C plenum demister adapter 19E662 1 Remove the screw Remove the A C plenum demister adapter is insert tool in slots push forward pull hose out pushing forward will pinch the tabs together 5 Thanks go out to Nick for the pics below bp Boe age SAA HE y g AA Meee GU or Spas CG ne The heater core pipe with the clip installed shows the two sided clip with the pressure points exposed I placed an X on the pressure point of the clip that you push the special tool against to release the Page 17 hose from the plastic clip d a New heater hose with new plastic clip o ring Spacer and o ring installed Top pic shows proper installation method Load up the old hose just like this then press on to the newly installed core pipes sticking out through the firewall Snaps right2. on 6 Disconnect the vacuum line 6 7 7 Remove the heater core bracket more of a housing cover than a bracket 1 Remove the two screws 2 Remove the bracket Its much easier doing this without the dash in the cab but you saved lots of time and effort not taking it all the way out Be patient getting all those screws out of the heater core housing I used a 1 4 ratchet 7mm socket screwdriver combination wrench Be creative Page 18 8 Remove the plenum assembly top Lots of screws I removed the black elect box above the heater plenum to ease access just two small screws size 7 32 then move it out of the way 1 Remove the 13 screws Could be more screws on later models 2 Remove the plenum assembly top Core is highlighted 9 Remove the blend door assembly from the case Pick straight up after releasing the tab at the top right side the door hinges on a gear on the bottom left 10 Remove the heater core It s a little pull to get the plastic tabs through the firewall foam if they re still on the pipes The new core needs to be wrapped with foam tape you ll see it on the old core when you get it out It keeps it from rattling inside against the plastic plenum housing Try to talk the parts guy into just giving you a strip of it when you buy the heater core OK NOW EVERYTHING IN REVERSE TO INSTALL THE NEW CORE AND DASH Wrap the new core with foam tape like the old one and put it in What time ts
3. 1997 Ford F 150 4 6 97 Expedition w addendum0O01 Heater Core Replacement Instructions c o Ford Technical Service Publication Service Manual After using the unedited original from a forum reader I added lots of extra notes and tips after completing the heater core job on my own 97F150 4 6 4x4 I am not a paid Ford mechanic Please use at own risk I crossed out the steps that are required if you completely remove the dash but may be unnecessary if your not going to remove it that s your choice I do not endorse the use of these instructions by individuals not qualified or certified to repair service Ford vehicles Ok that s my legal disclaimer But first here are some very important warnings that you must not skip They are copied directly from the instructions but I also put them here so I can sleep at night WARNING ALWAYS WEAR SAFETY GLASSES WHEN REMOVING AND HANDLING AN AIR BAG ALWAYS CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP WARNING TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS TO DEPLETE THE BACKUP POWER SUPPLY ENERGY DI NNECT THE BATTERY TO STARTER RELAY CABLE AND WAIT ONE MINUTE Page 1 Here s a list of tips before you
4. EAR SAFETY GLASSES WHEN REMOVING AND HANDLING AN AIR BAG CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP 27 Remove the passenger side air bag module A little spooky but I survived I carried it like dynamite Lol 3 screws 1 elect plug 1 Remove the three passenger side air bag module screws Save these too stick them in a baggie and tape it to the airbag module 2 Disconnect the passenger side air bag module electrical connector 3 Remove the passenger side air bag module 28 Remove the four RH assist handle screw covers 28 29 bag em msi Y 29 Remove the four RH assist handle screws These are tricky to reinstall use a magnetic screwdriver to hold the screws or a piece of sticky tape on the screwdriver so you don t drop the screw back down behind the trim piece 30 Remove the RH assist handle Page 11 31 Remove the RH windshield side garnish moulding 32 Remove the instrument panel bolt below and to the left of the glove compartment 32 33 Remove both instrument panel bolts behind the passenger side air bag module opening Page 12 34 Remove the two instrument panel bolts on the top of the instrument panel 1 Remove the two covers 2 Remove the two bolts 35 36 Remove the instrument panel bolt
5. below and to the left of the cigar lighter and power point Page 13 37 38 39 40 41 Remove the instrument panel nut on the bottom RH corner of the instrument panel 37 and 38 are two larger bolts next on each side of the dash at the doors Don t lose these need I say Bag em I 37 38 Remove the instrument panel nut on the bottom LH corner of the instrument panel Remove the instrument panel bolt under the center of the steering column You can see it when you lower the steering column Remove the instrument panel bolt on the bottom LH side of the instrument cluster opening Page 14 z OPTIONAL OPTIONAL gt az FAJLO ot RI 2466 4 44 Remove the instrument panel from the RH floor brace Page 15 45 Note Two technicians are required to perform this step Pull the door rubber on both door frames out of the way of the dash OK now drop the steering col down on the seat Yeah its heavy so with both doors open pull the dashboard out from its slots under the front window and swing the passenger side out as far as it will go On the right you ll be connected by the antenna cable it will give you enough slack if you tied a shoelace to it and pulled into the cab just what you need need more Unhook the cable from the dashboard where its tied into place The driver side doesn t need to move out very far maybe a few inches Remove the instrument panel Optiona
6. e heads for sockets and screws A magnet tool for retrieving that socket you cant reach Short rubber hose for the radiator drain plug A magnet bowl its pretty handy item to hold screws and small sockets Page 2 Make sure that the temperature control is set only to cool not Max Cold 0900 position is ok that s straight out to the left prior to getting started that takes a lot of pressure off the blender door for eas removal 1 Disconnect BOTH the battery Positive and Negative Ground cables can you say airbags BOOM Disconnect Both Cables Note When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy 2 Drain the radiator Attach a short rubber hose to the drain it helps in your efforts to keep the fluid off your driveway Section 501 12 INSTRUMENT PANEL AND CONSOLE gt REMOVAL AND INSTALLATION Installation To re install simply just reverse the removal procedure 1 WARNING TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS TO DEPLETE THE BACKUP POWER SUPPLY ENERGY DISCONNECT THE BATTERY TO STARTER RELAY CABLE AND WAIT ONE MINUTE 2 Note On vehicles equipped with automatic transmissions move the shift lever to the 1 pos
7. get started I got a lot of advice and help from Ford truck forums so I am just returning the favor Shopping list from FORD dealer 15 00 for 2 sets of heater hose o rings and snap clips 40 00 heater core cheaper at the dealer but no warrantee aftermarket parts store model preferred by many 55 insulated foam tape to wrap new core with parts dept just gave me what I needed and a gallon of anti freeze 1 Tying off the antenna cable to a old shoelace was a great little trick that made the reassembly a snap allowed pulling antenna cable back out of the hole real easy used elect tape too didn t want ANY surprises later 2 Get the heater hose removal tool from a mechanic willing to loan it out to you was surprised at the helping hand the dealer mechs were The tool took a few minutes to figure out Took a second trip back to the Ford dealer for replacement o rings and clips save time buy these first cause you ll break the originals if you dont change em anyway your in this deep 2 A Another method without using the tool is just cutting off the inlet and outlet pipes from the heater core with a saws all and pulling the hose pipe out from the engine compartment side This is done after the H Core plenum is removed got so frustrated without the special tool nearly did this too 3 Leave all the steering column and large bulkhead elect plugs attached unhooked these before the Ford mechanic advised me not to mess wi
8. it Your half way there And they said this was hard Page 19 Addendum 001 Addition for 97 Expedition Owners Heater Core Removal Procedure Perform these steps after lowering steering column step 23 1 Carefully pry to release the four clips and remove the center instrument panel finish panel 2 Remove the radio chassis Insert Radio Removal Tool two pieces of heavy wire coat hanger bent in a long U into the radio face plate and release the radio retaining clips and pull outward on the Radio Removal Tool while pulling the radio chassis away from the instrument panel oF Disconnect the radio antenna lead in cable 18812 and the radio wiring connectors 4 To install reverse the removal procedure Now back to Step 25 Ignore 24 Page 20
9. ition to ease removal of the steering column top opening cover ALWAYS A Good idea to put wood blocks at the rear wheels so you don t roll away Carefully pry to release the A four clips and remove the B steering column TOP opening cover Page 3 3 Position the electrical connector aside e Release the push clip from the lower instrument panel steering column cover l 4 Pull to release the three A clips and remove the B fuse door Page 4 6 7 5 Position the hood latch release handle aside Steps 5 amp 6 Start bagging those screws for safe keeping 1 Remove the two hood latch release handle screws 2 Remove the hood latch release handle Position the parking brake release handle aside 1 Remove the two parking brake release handle screws 2 Remove me parking brake release handle ig Remove the instrument panel floor duct panel e Remove two push clips and release one expander clip Page 5 Ti Remove the lower instrument panel steering column cover 04459 TIP KEEP THESE 6 SCREWS TOGETHER 1 Remove the six lower instrument panel steering column cover bolts 2 Remove the lower instrument panel steering column cover 9 Remove the LH and RH door scuff plates 10 Remove the LH and RH cowl side trim panels 11 Disconnect the brake on off BOO switch electrical connector Located above the brake pedal now your getting into it ru r Now Skip to step 16 If you ch
10. l just move it out as far as you need to access behind the dash on the passenger side set the right side on the passenger seat move seat forward as needed It s much easier without the dash in the cab but you saved lots of time not taking it all the way out Be patient getting all those screws out of the heater core housing I used a ratchet 7mm socket screwdriver comb wrench Be creative you ll notice the elect box that sits on the top of the housing when you try to pull it out Just remove the 2 5 16 screws and push it out of the way PROBLEMS If the dash seems to be stuck just search for a screw that may not be listed here I found one near the center of the dash You can pull gently rocking up down side to side on the dash to tell where it is binding up or where it is still attached Page 16 5 HEATER CORE REMOVAL Steps 1 2 and 3 are already completed back at the beginning battery radiator dash OK Just so you don t think there s something missing here 4 Compress the holding tabs in engine compartment up against the firewall just below the dash use a flashlight to see them see photos on next page and disconnect the heater water hoses at the heater core Alan s Note Since I didn t have the special tool I just cut off the two heater core supply and return tube inside the cab using a small hack saw GET THE SPECIAL TOOL FROM A FORD MECHANIC I DID I added what the tool looks like NOTE The
11. oose as I did not to completely remove the dash OPTIONAL STEPS 12 15 NOT NEEDED if you don t remove the dash You just need to pull it out from the passenger side enough to access the heater core plenum Let me just Say this is a lot of unnecessary work if you choose to do it anyway Page 6 a R12460 A 13 Skip this Disconnect j j OPTIONAL OPTIONAL LD OPTIONAL Oh yeah right this is a pain I stopped here and got some professional consultation Only to find out I didn t have to do this Please continue your doing great Page 7 20 16 Disconnect the two air bag diagnostic monitor electrical connectors Steps 16 20 disconnect all plugs and ground wires on the RH Passenger floorboard some may not be listed here user tip use masking tape to label matching ends of these plugs 17 Disconnect the inertia fuel shutoff switch electrical connector 18 Remove the two grounds from the RH cowl i Disconnect the climate control head vacuum line connector Page 8 21 Remove the inst panel steering column opening cover reinforcement 13mm deep socket 1 Remove the four instrument panel steering column opening cover reinforcement nuts 2 Remove the instrument panel steering column opening cover reinforcement 22 If equipped disconnect the transmission range indicator from the steering column Remove the bolt 2 Disconnect the cable 21 23 Lower the
12. steering column 3C529 I left in 1 nut just a couple threads to hold this up until I was ready to pull out the dash then I just laid the steering col on the front seat 1 Remove the four steering column support nuts 13mm x 4 2 Lower the steering column Slowly Note For 97 Expeditions See AddendumOOl1 last page Removal of Radio Chassis Page 9 24 Note i Disconnect the antenna cable from the outside of the vehicle The black plastic cover just snaps down over the antenna base carefully pry it off and expose 3 screws remove them and pull the antenna cable out like a stereo plug Connect the cable to a shoelace or cord and feed it back down the hole giving it some slack that s needed when you have to pull on it to move the dash away from the passenger side NOTE Have your cord and tape ready before you unhook it I dropped the cable back in the hole but was able to retrieve it with a tool grabber I love my tools CONNECT A WIRE OR CORD TO THE WIRE CABLE You ll use it to pull the cable back out when your done I tied it to a leather shoelace and taped it too 25 Remove the instrument panel relay cover Careful with step 2 its pretty easy to break the little tabs on the sensor oops 1 Remove the instrument panel relay cover 2 Disconnect the auto lamp sensor electrical connector if equipped 5 a y 26 Open the glove compartment and release the two doorstops Page 10 WARNING ALWAYS W
13. th them 4 Try to follow in reverse the dash removal instructions during reassembly so you dont have any do overs when you cant get a screw to line up properly Don t ask how now this 5 Get a large box for all the trim parts 6 Updated tip To help to figure out where all the screws go am recommending an idea from a user of this heater doc who offered this tip wish had used this method myself had 3 left over no rattles Tip if you have a helper have them read the steps aloud while you perform them and also have them put the screws removed in baggies labeled with the corresponding number of the step 7 removed the big elect housing located right over the heater core housing to aide in getting the cover reinstalled it was in the way when was reinstalling the plenum cover 2 screws no big deal Important hint if you cant reach the spot to start a screw by hand Use either a magnet screw tip or a piece of tape sticky foam That will do the trick when reaching those backside screws on the heater cowling cover this is not the time to tear the dash back out to get a amp little screw that dropped off the screwdriver or out of the socket Tools used priceless Battery op drill w socket adapters extensions really speeds things up Sockets 5 16 7mm 8mm 10mm for dash screws 13mm for the steering col nuts Flashlight a must for searching for black screw heads under the dash Screwdriver w changeabl
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