Anyone who has actually tackled heater main point replacement will certainly tell friend they’d rather have an all-night source canal than have to perform this dreaded task. Heater main point leakage starts with the subtle aroma the antifreeze and evolves right into a tiny wet point out on the driveway. By the time you have coolant ~ above the pavement there is no method around it. You’re going to have to replace the heater core or fill up on protect against Leak.

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Back in the day, on older Ford F-Series trucks, heater main point placement affiliated going increase under the dashboard and removing the heating and also air-conditioning unit. In the ’70s, Ford began installing HVAC systems prior to dashboards to be bolted into the vehicle. Dashboards, which to be preassembled top top rotisseries, were installed in the auto via an installation fixture and a couple of assembly workers. This approach made automobile assembly easier and quicker. However, it additionally meant considerable labor because that the technician confronted with heater main point and/or air-conditioning evaporator replacement.


We’re working with a ’98 Ford F-150 with virtually 267,000 mile on the odometer after 18 year of service. That’s pretty good, considering most F-Series trucks have experienced chronic heater core failure previously in their business lives. Heater cores have constantly been a weak spot in Ford vehicles for various reasons, including excessive cooling system pressure and volume, which has been improved in production via the use of heater hose restrictors between the engine and also heater core.


Heater main point replacement in the F-Series, Expedition, and also Lincoln Navigator requires removal that the dashboard to wherein it can be disconnected and also swung away from the HVAC unit bolted come the firewall. Some technicians have managed to unbolt the dashboard and swing it out far sufficient to gain access to the HVAC unit. Others disconnect the steering column and also remove the whole dashboard for simpler access. That is said you use actual Motorcraft parts where possible, i m sorry are obtainable from rock Auto, in your heater main point replacement, including cooling device hoses, which have actually the factory-style fast connections at the firewall. Motorcraft heater hoses likewise have the flow-restrictor in the “in” hose designed to stop heater core failure native pressure and also excessive flow. No all aftermarket replacement heater hoses have this restrictor. Heater hose quick-connects are anything yet “quick” disconnect. You’re going to require the quick-disconnect tool obtainable at any kind of auto components store or Summit gyeongju Equipment. If you’re replacing the heater hoses, girlfriend can reduced the quick-connect tabs and also pull the connectors.


Although we’re working through a ’97-to-’03-generation F-Series truck, simple principles of replacement space the very same from because that ’97-to-’17 models. Let’s gain started.


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See all 27 photosIn the attention of safety, the first order of business is come disconnect the battery before performing any disassembly. Drain the cooling system and properly dispose of any coolant. Seat and also jack bracket removed is said for improved accessibility to the dashboard and HVAC assembly. A Torx wrench is compelled to eliminate seats and also seatbelts. It is a an excellent idea to have the cooling device flushed before heater core replacement.
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See every 27 photosRocker sill molding removal is easy. It pops in and out with no tools required. Absent panel removal, which mister in and out, is next to gain accessibility to wiring and modules, which have to be disconnected indigenous the dashboard.
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See every 27 photosWe removed the A-pillar panel and handhold because that improved accessibility and photographic purposes, however you won’t need to do this.
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See all 27 photosThis versatile dash lid on top needs to be removed carefully. If you get aggressive v this piece, it will crack—especially as soon as you consider how old these trucks are today. Plastic components become very brittle and also can crack end time. Retaining tabs were initially coated v white grease for simple installation and also removal.
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See all 27 photosAirbag remove is performed through the removal of three bolts (two bottom and also one top), making use of a 10mm socket. We have removed the gloves compartment door for picture purposes, however you won’t have actually to. Tabs in ~ the top of the glovebox door deserve to be carefully bent to every side, which enables you to reduced the door far sufficient to accessibility airbag bolts and also dash screws.
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See every 27 photosWith the 3 bolts removed top and also bottom, the airbag assembly comes appropriate out. A two-pin plug associate the airbag. We caution you have to be an extremely careful through airbags throughout service. Save them facedown in a protected location. Also static power can cause an airbag come fire.
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See every 27 photosAirbag bolt areas on ’97-to-’03 F-150s room in three locations (arrows).
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See all 27 photosPassenger-side airbag looks like this indigenous behind. Yes sir a two-pin connector tied come the canister inside the module. Exercise excessive caution v 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 tower for ease of access. The steering tower cover pops the end without tools.
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See every 27 photosThe bezel above the instrument swarm is attached with three screws making use of a 7mm socket. When these screws space removed, the bezel pops appropriate out.
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See every 27 photosYou will discover the dashboard is tied come the human body via seemingly dozens of these sheetmetal screws (dozens!), i beg your pardon are eliminated with a 7mm socket. Follow these screws about the perimeter that the dashboard. Castle secure the dashboard to the body. The F-150 dashboard is composed of the covering you see, backed by a plastic within frame/ductwork assembly tied come a steel framework at the cowl. Gold cad-plated dash screws space coarse thread because that threading into plastic. Black color or herbal cad-plated fine-thread screws are situated at copper-plated (metal) inserts.
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See all 27 photosThe instrument cluster is eliminated for improved access. Some technicians remove the whole dashboard to do it less complicated to obtain to the HVAC assembly, however you don’t need to do that. The objective is come remove sufficient of the perimeter screws so you have the right to swing the dashboard out of the way. Be really careful through 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 also is removed as displayed to fall the steering column.
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See every 27 photosThere are four steering column support studs. This is one integral part of the collapsible steering column.
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See all 27 photosThe dash pad “bubble” is gotten rid of next. Back this looks favor a padded dash, it is little an ext than a removable shell. Usage a 7mm socket to remove these black cad screws.
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See all 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 the the way, heater core access becomes easy. A collection of screws secure the peak of the HVAC plenum, which is removed for heater core and air-conditioning evaporator access. Friend will require a 10mm socket because that this purpose.
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See all 27 photosWhile she performing heater core replacement, it is a good idea to inspect blower motor and variable resistor status. Both are basic to access with the dashboard installed, which means you don’t have to replace them in ~ this time. We’ve opted for a Motorcraft heater core. However, the manufacturing facility heat mix door has actually a weak spot at its pivot and should be replaced. The pivot allude at the blend door actuator tends to crack and also break, i m sorry is why we’re arguing the Dorman heat blend door kit (#902220 or #902207) for her F-150 heater main point service. The aluminum pivot ~ above the Dorman replacement is solid and also will no fail. It is likewise suggested you change the blend door actuator.
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See every 27 photosThe variable resistor package is what affects fan speed, not the fan switch. Fan power is routed through this resistor package to control fan speed.
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See every 27 photosWe’ve chosen the Motorcraft heater core largely for reasons of guarantee fitment. The aftermarket likewise offers instead of heater cores because that F-150s.

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See every 27 photosThe original factory heater blend door assembly, i m sorry pops out without tools, is removed and replaced through the enhanced Dorman blend door assembly.
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See all 27 photosThe installed Motorcraft heater main point is equipment with new foam roughly its perimeter. The arrowhead indicates wherein the heater mix door splines right into the electric actuator below. It is difficult to download the blend door any means but the appropriate way. The HVAC cap is reinstalled using a 10mm socket.
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See all 27 photosThe new Dorman heater blend door is set up as shown. Reinstall the HVAC cap and also dashboard/steering column.
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