F 250 4WD HD Pickup V8-460 7.5L VIN G EFI (1997)
Housing Assembly HVAC: Service and Repair
With Manual A/C-Heater
SPECIAL SERVICE TOOL(S) REQUIRED
Spring Lock Coupling
Description
Tool Number
Spring Lock coupling Disconnect Tool Set
T84L-19623-B
REMOVAL
1. Disconnect the battery ground cable.
NOTE: Cap all open refrigerant lines and components to prevent entry of dirt and moisture into the A/C system.
2. Recover the refrigerant system using approved recovery equipment. See: Service and Repair/Refrigerant Recovery
3. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
4. Disconnect vacuum supply hose at dash panel. Position the A/C vacuum check valve away from A/C evaporator case.
5. Disconnect condenser to evaporator tube from the A/C evaporator core using Spring Lock Coupling Disconnect Tool Set T84L-19623-B.
6. Disconnect A/C manifold and tube from suction accumulator/drier.
7. Disconnect heater water hoses from heater core and plug heater water hoses.
8. Working in passenger compartment, remove two screws or nuts retaining bottom of A/C evaporator case to dash panel. One screw also retains
lower edge of A/C evaporator case to dash panel.
9. Unplug A/C plenum vacuum harness and two wiring connectors to main wiring located near right end of A/C plenum vacuum harness coming from
recirc. duct opening back into opening.
10. Remove two screws retaining right side of recirc. duct to dash panel.
11. Remove two retaining nuts retaining A/C evaporator case and recirc. duct to dash panel.
12. Pull A/C evaporator case and recirc. duct forward and remove from vehicle.
13. Remove the heater outlet floor duct from heater air plenum chamber.
14. Remove four fasteners that retain the left end of the heater air plenum chamber to the dash panel.
15. Disconnect A/C temperature cable and vacuum connector at A/C control.
16. Disconnect source vacuum block secured to the right of the heater core cover.
17. Pull heater air plenum chamber forward to disengage three studs from dash panel.
18. Lower heater air plenum chamber from its location under the instrument panel.
NOTE: Care must be taken to avoid spilling any coolant from heater core.
INSTALLATION
1. Position heater air plenum chamber against dash panel. Install one screw to retain the left end of heater air plenum chamber to dash panel.
2. Position A/C evaporator case against dash panel, making sure the studs are inserted through holes in dash panel and flange.
3. Position instrument panel and tighten its retaining screws.