A/c-Heater System - Automatic: Removal & Installation Ford Expedition I

REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove drive belt. Turn air suspension off (if equipped). Remove manifold-to-compressor bolt. Remove manifold and tube assembly from compressor. Raise and support vehicle. Disconnect crankshaft position sensor connector. Disconnect A/C compressor electrical connector. Remove A/C compressor bolts. Remove A/C compressor. To install, reverse removal procedure.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove radiator. Disconnect condenser inlet and outlet lines. Plug openings immediately. Remove condenser.
2. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Add one ounce of new refrigerant oil to condenser prior to installation.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove manifold-to-compressor bolt and remove manifold and tube assembly from compressor.
2. Disconnect A/C pressure cut-off switch connector. Disconnect manifold and tube line fitting from accumulator-drier. Plug openings immediately. Disconnect peanut fittings at line attachments on condenser. Remove refrigerant lines from condenser. Plug all openings. Remove A/C pressure cut-off switch. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove junction block splash shield. Disconnect cable ends from starter relay. Remove junction block bracket. Disconnect A/C cycling switch connector on top of accumulator-drier.
2. Using backup wrench, disconnect refrigerant line connection from accumulator-drier. Plug all openings. Remove bracket clamp bolt. Disconnect evaporator-to-accumulator refrigerant line. Remove accumulator-drier from vehicle.
3. To install, reverse removal procedure. Drill 2 holes in bottom of old accumulator-drier to drain and measure refrigerant oil. Add same amount, plus 2 more ounces, of new refrigerant oil to replacement accumulator-drier.

Removal & Installation (Front A/C-Heater System)

1. Disconnect negative battery cable. Remove instrument panel center finish panel (4 clips).
2. Disconnect 4WD control switch connector (if equipped). Remove 4 A/C-heater control panel assembly screws. Pull out A/C-heater control panel. Disconnect electrical and vacuum line connectors. To install, reverse removal procedure.

Removal & Installation (Front Auxiliary A/C-Heater System)

Remove screw in center of roof console. Carefully release 3 clips and slide roof console forward. (Scheme 11) Disconnect electrical connectors. To install, reverse removal procedure.

Scheme 11

Removal & Installation (Rear Auxiliary A/C-Heater System)

Slide control panel assembly forward and downward from roof panel. Remove control panel. Disconnect electrical connectors. To install, reverse removal procedure.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain radiator. Remove instrument panel. See «INSTRUMENT PANEL»(ref-238-S36742433392000030800000). Disconnect hoses at heater core. Disconnect refrigerant lines to evaporator.
2. Remove right A/C plenum demister adapter. Remove heater core outlet bracket. Remove 14 plenum top screws. Remove plenum assembly top. Remove evaporator core. (Scheme 12) To install, reverse removal procedure.

Scheme 12

Remove rear auxiliary A/C-heater assembly. See A/C-HEATER ASSEMBLY . Remove 10 evaporator/heater core access cover bolts. Remove access cover. Remove evaporator and/or heater core. To install, reverse removal procedure.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove condenser-to-evaporator refrigerant line.
2. Engage Fixed Orifice Tube Remover/Replacer (T83L-19990-A) to fixed orifice tube. Hold "T" handle steady and turn body of tool to remove fixed orifice tube.
3. If fixed orifice tube is broken, use Broken Orifice Tube Extractor (T83L-19990-B) to engage and remove the broken part. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil.

1. Disconnect negative battery cable. Drain radiator. Remove instrument panel. See «INSTRUMENT PANEL»(ref-238-S36742433392000030800000) . On 5.4L engines, remove junction block splash shield. Disconnect cable ends from starter relay. Remove junction block bracket. On all engines, compress heater core hose holding tabs. Disconnect heater hoses at heater core. Remove A/C plenum demister adapter screw. Remove A/C plenum demister adapter. Disconnect vacuum line.
2. Remove 2 heater core bracket screws. Remove heater core bracket. Remove 14 screws from plenum assembly top. Remove plenum assembly top. Remove blend door assembly from case. Remove heater core. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-238-S06525685042000030800000) .

Disconnect negative battery cable. Remove passenger side sound insulator. If equipped, remove aftermarket air filter cover, filter and bracket. Disconnect christmas-tree retainer from motor mounting plate. Disconnect connector from blower motor cover. Remove 3 cover screws, pry up 3 release tabs and remove cover. Remove 3 retaining screws and remove blower motor. To install, reverse removal procedure.

Disconnect negative battery cable. Remove floor console support braces (8 screws). Remove blower motor duct. Remove 3 nuts and blower motor assembly. Disconnect electrical connectors. Remove blower motor resistor. Remove blower motor lower duct cover and remove duct. Remove blower motor. To install, reverse removal procedure.

Disconnect negative battery cable. Remove left quarter trim access cover. Disconnect electrical connector, remove 3 cover bolts, and remove blower motor cover. Remove retaining bolts and remove blower motor. To install, reverse removal procedure.

Removal (Front A/C-Heater System)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain radiator. Remove instrument panel. See «INSTRUMENT PANEL»(ref-238-S36742433392000030800000). Disconnect heater hoses at heater core.
2. Disconnect refrigerant lines to condenser. Remove 2 A/C-heater housing assembly nuts from engine compartment side. Disconnect vacuum hose from vacuum check valve. Remove 2 interior housing assembly nuts. (Scheme 13) Remove A/C-heater assembly.

Installation

1. Position assembly in place. Install 2 nuts. Connect vacuum check valve hose. Install 2 nuts from engine side. Check tube lock coupling spring for damage. Install new spring if old one is damaged or missing.
2. Clean all fittings. Install new "O" rings lubricated with clean refrigerant oil. Install plastic indicator ring into cage opening if an indicator ring is used.

Scheme 13

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain radiator. Remove left quarter trim panel. Disconnect electrical connectors from plenum assembly. Disconnect heater core hoses.
2. Remove evaporator case drain hose. Disconnect refrigerant lines from A/C evaporator expansion valve. Plug line openings. Remove push-pin and remove vertical A/C outlet duct. Remove 3 assembly retaining bolts. Remove auxiliary A/C-heater assembly. (Scheme 14) To install, reverse removal procedure.

Scheme 14

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain radiator. Remove left quarter trim panel access cover. Disconnect evaporator core tubes from expansion valve. Remove expansion valve. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove console tray mat. Remove console tray front screw. Remove console tray rear screw. Remove console tray. Remove center console front bolts.
2. Disconnect center console electrical connector. Remove 2 rear center console bolt covers. Remove 2 rear console bolts. Lift front of console and slide rearward to disengage floor brackets. Remove center console. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Move power seats rearward (if equipped). Move adjustable pedal to full rearward position (if equipped). Release mounting tabs and position power distribution box aside. Remove 3 bolts and remove bulkhead electrical connectors in engine compartment.
2. From inside vehicle, remove bulkhead electrical connector insulator and unclip bulkhead electrical connectors from dash panel. Remove front floor console (if equipped). Remove steering column cover. Remove valance panel. Disconnect blend door electrical connector. Disconnect climate control panel vacuum harness. Remove left and right sill plates. Remove left and right kick panels. Remove right side assist handle. Remove left and right windshield garnish moldings. Disconnect brakelight switch electrical connector.
3. Disconnect adjustable pedal motor electrical connector (if equipped). Remove radio and generic electronic module ground bolts. Disconnect left side main wiring harness and bulkhead connectors Remove steering column opening cover reinforcement. Disconnect air bag sliding contact and anti-theft electrical connectors. Disconnect remaining electrical connectors from steering column.
4. Disconnect transmission range indicator from steering column (if equipped). Remove steering column support nuts. Lower steering column. Remove instrument panel attaching bolts through steering column opening. Remove instrument panel reinforcement bolt below left corner of cigarette lighter. Disconnect fuel inertia fuel shut-off switch connector. Remove right side ground bolt. Disconnect air suspension switch electrical connector (if equipped).
5. Disconnect right side main wiring harness connectors. Disconnect blower motor electrical connectors. Release locking tab and disconnect restraint control module electrical connector. Remove hose from evaporator case. Remove right fender splash shield away from dash panel. Disconnect antenna lead from antenna base and feed cable through cowl side panel (loosen grommet). Remove instrument panel relay cover. Remove glove box.
6. Wearing safety glasses, disconnect passenger side air bag module connector. Remove passenger side air bag module screws. Remove passenger side air bag module. Remove instrument panel reinforcement bolt below and to left of glove box. Remove instrument panel bolts behind passenger side air bag module opening.
7. Remove instrument panel bolt on relay bracket. Loosen instrument floor brace bolts and nuts. Remove left and right instrument panel cowl nuts. Remove defroster grille assembly and instrument panel cowl top bolts. With an assistant, remove instrument panel. To install, reverse removal procedure.

Scheme 15

Disconnect negative battery cable. If equipped, remove floor duct panel. Disconnect connector and remove screws from electronic blend door actuator. Pull actuator down to release actuator shaft. Remove actuator. To install, reverse removal procedure.

Disconnect negative battery cable. Disengage stops and lower glove box door. Disengage blower motor speed controller mounting bracket from instrument panel. Disconnect connector, disengage 2 retaining tabs and slide blower motor speed controller from bracket. To install, reverse removal procedure.

Disconnect negative battery cable. Remove instrument panel upper finish panel. Disconnect connector and remove sunload sensor from finish panel. To install, reverse removal procedure.

Disconnect negative battery cable. Remove center instrument panel finish panel (4 clips). If equipped, disconnect 4WD control switch connector. Remove steering column cover panel. Remove headlight switch. Remove left side instrument panel finish panel. Remove 2 screws and remove accessory outlet trim panel above cigarette lighter. Remove 2 screws, disconnect electrical connector and remove in-car temperature sensor from its hose. To install, reverse removal procedure.

Disconnect negative battery cable. If equipped, removal floor duct panel. Disconnect vacuum hose connector and remove screws from vacuum motor. Rotate vacuum motor to disconnect motor rod from panel/floor door, slide rod out of door and remove panel/floor door vacuum control motor. To install, reverse removal procedure.

Disconnect negative battery cable. Remove A/C-heater assembly. See A/C-HEATER ASSEMBLY . Disconnect vacuum line from air inlet door vacuum motor. Remove retaining screws, rotate vacuum motor to disengage control rod from door lever, and remove air inlet door vacuum control motor. To install, reverse removal procedure.