Auxiliary Climate Control: Removal & Installation Ford Expedition II

Removal and Installation

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Remove the auxiliary climate control housing. For additional information, refer to «AUXILIARY CLIMATE CONTROL HOUSING»(ref-209926-S13627275232005121200000) .
2. Disconnect the A/C fittings and remove the thermostatic expansion valve (TXV). Discard the O-ring seals.
3. Remove the screws and the evaporator/heater core access cover.
4. Remove the A/C evaporator core (19860).
5. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean PAG oil.

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1. Disengage the clips and remove the overhead console. Disconnect the electrical connectors.
2. Remove the screws and the map lights.
3. Remove the screws and the front auxiliary climate control assembly.
4. To install, reverse the removal procedure.

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1. Open the front floor console cover and remove the screws.
2. Open the cup holder and remove the screw.
3. Disengage the clips and remove the floor console rear finish panel. Disconnect the electrical connectors.
4. Remove the screws and the rear auxiliary climate control assembly.
5. To install, reverse the removal procedure.

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1. Fabricate a removal tool from a 1/8-inch diameter rod.
2. Rotate the A/C register with the removal tool to align the retaining ears with the clearance openings and remove the A/C register.
3. To install, reverse the removal procedure.

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1. Remove the auxiliary climate control housing. For additional information, refer to «AUXILIARY CLIMATE CONTROL HOUSING»(ref-209926-S13627275232005121200000) .
2. Remove the screws and the evaporator/heater core access cover.
3. Remove the heater core.
4. To install, reverse the removal procedure.

Removal

Note. The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation.

Note. The following procedure can be used to remove and install one of, or both the auxiliary heater inlet line and auxiliary heater outlet line. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

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1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-209901) .
2. Remove the RH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-209953) .
3. Detach the auxiliary heater lines. Disconnect the heater hose(s). Remove the bolts. Remove the line bracket.
4. Remove the spare tire.
5. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
6. Remove the RH front wheel.
7. Remove the RH fender splash shield.
8. Disconnect the heater hose(s).
9. Remove the muffler. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
10. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
11. Remove the three bolts and the heat shield.
12. Remove the bolts.
13. Remove the nut and the line bracket.
14. Remove the bolt and the heat shield.
15. Remove the nuts and the remaining line brackets.
16. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s).
17. Remove the auxiliary heater line(s) in three separate pieces.

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1. Partially lower the vehicle.
2. Attach the rear portion of the auxiliary heater lines. Connect the heater hoses. Install the line bracket. Install the bolts.
3. Install the front auxiliary heater line(s) and connect the heater hose(s). Clean and lubricate the heater hoses with Coolant Hose Lubricant or plain water only if needed.
4. Raise the vehicle.
5. Install the middle auxiliary heater line(s).
6. Starting from the rear of the vehicle, install the first three line brackets.
7. Tighten the middle auxiliary heater line fittings.
8. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed.
9. Install the heat shield and the bolts.
10. Install the heat shield and the bolts.
11. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
12. Install the muffler. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
13. Partially lower the vehicle.
14. Install the heat shield bolt.
15. Install the line bracket.
16. Lower the vehicle.
17. Install the spare tire.
18. Install the RH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-209953) .
19. Fill the engine coolant level. For additional information, refer to «ENGINE COOLING»(ref-209901) .

Note. The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation.

Note. The following procedure can be used to remove and install one of, or both the auxiliary evaporator inlet line and auxiliary evaporator outlet line. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Remove the nut(s) and disconnect the A/C fitting(s).
3. Remove the RH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-209953) .
4. Remove the spare tire.
5. Disconnect the A/C fittings. Install new O-rings lubricated in clean PAG oil.
6. Remove the bolts and the line bracket.
7. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
8. Remove the spare tire carrier splash shield.
9. Remove the RH front wheel.
10. Remove the RH fender splash shield.
11. Remove the muffler. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
12. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
13. Remove the three bolts and the heat shield.
14. Remove the bolts.
15. Remove the nut and the line bracket.
16. Remove the bolt and the heat shield.
17. Remove the nuts and the remaining line brackets.
18. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s).
19. Remove the auxiliary evaporator line(s) in three separate pieces.

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1. Partially lower the vehicle to allow access to both the rear auxiliary line fittings and the underside of the vehicle.
2. Position the rear portion of the auxiliary evaporator line(s) and install the line bracket and bolts.
3. Connect the A/C fittings.
4. Install the front auxiliary evaporator line(s) and connect the A/C fittings. Install new O-ring seals lubricated in clean PAG oil.
5. Raise the vehicle.
6. Install the middle auxiliary evaporator line(s).
7. Starting from the rear of the vehicle, install the first three line brackets.
8. Tighten the middle auxiliary evaporator line fittings.
9. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed.
10. Install the heat shield and the bolts.
11. Install the heat shield and the bolts.
12. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
13. Install the muffler. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
14. Partially lower the vehicle.
15. Install the heat shield bolt.
16. Install the line bracket.
17. Install the spare tire carrier splash shield.
18. Install the RH front fender splash shield.
19. Install the RH front wheel.
20. Lower the vehicle.
21. Install the RH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-209953) .
22. Install the spare tire.
23. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
24. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .