RAM 1500 Truck 4WD V8-5.9L VIN Z (2002)
Housing Assembly HVAC: Overhaul
DISASSEMBLY
1. Remove the HVAC housing from the vehicle and place it on the workbench. See: Removal and Replacement
2. Unplug the electrical connectors from each actuator.
3. Remove the HVAC assembly wiring harness from the HVAC case.
4. Remove the blower motor and blower wheel unit from the HVAC housing. See: Blower Motor/Service and Repair
5. Remove the heater core mounting screws and carefully remove the heater core assembly. See: Heater Core/Service and Repair
6. Carefully remove the foam seals from the heater core and evaporator coil tube mounting flange of the HVAC housing. If the either seal is
deformed or damaged it must be replaced.
7. Use a screwdriver to pry off the four snap clips that help secure the upper and lower HVAC housing halves together.
8. Remove the screws that secure the upper and lower HVAC housing halves together.
9. Carefully separate the upper HVAC housing from the lower half.
ASSEMBLY
1. Assemble the upper HVAC housing half to the lower half. During assembly be certain of the following.
a. That each of the mode door pivot shaft ends and the temperature blend door shafts are properly engaged in there pivot holes.
b. That the blower motor is properly indexed and installed.
c. If the unit is equipped with air conditioning, that the evaporator coil tube rubber seal is properly positioned in the grooves in both the upper
and lower HVAC housing halves.
d. That the evaporator drain opening is clean.
e. That the evaporator drain shield is installed correctly
2. Install the screws and snap clips that secure the upper and lower HVAC housing halves to each other. Tighten the screws to 2.2 Nm (20 in. lbs.).
3. Install the blower motor and wheel unit in the HVAC housing. See: Blower Motor/Service and Repair
4. Install the foam seals on the flanges around the heater core and evaporator coil tube mounting flange of the HVAC housing. Repair or replace any
seals as required.
5. Install the electrical wiring harness for the actuators. Make sure the wires are routed through all wiring retainers, replace any retainers that are
damaged.
6. Connect the wiring harness to each actuator, making sure each connector is securely attached.
