Auxiliary HVAC Ford Explorer Sport Trac II

Material

Material

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Auxiliary Climate Control

The auxiliary climate control system is a one-piece unit that is located on the LH side of the vehicle between the side windows and the floorpan, behind the rear wheel well. The driver has control of the auxiliary climate control system using the auxiliary climate control assembly.

All of the auxiliary climate control system components are serviceable from the inside of the vehicle except the lines.

Auxiliary System Air Distribution

A vertical air distribution duct supplies air to the integral headliner air distribution duct. Airflow is then directed to the passengers through adjustable registers. The floor duct supplies air to a fixed register which is integral to the side trim panel and directs airflow through the fixed register to the passenger compartment.

Scheme 206

The auxiliary climate control system has the following features

1. The auxiliary blower motor recirculates the air inside the vehicle. Outside air is not available to the auxiliary climate control system.
2. Air is cooled and dehumidified by the auxiliary evaporator core only if the instrument panel mounted climate control assembly is adjusted to a position that requires A/C compressor operation.
3. The temperature blend door and the air distribution mode door are controlled by electronic actuator motors.
4. Movement of the auxiliary temperature control between COOL and WARM causes a corresponding movement of the temperature blend door to direct blower motor airflow through and/or around the auxiliary heater core.
5. Toggling of the auxiliary air distribution control between PANEL and FLOOR causes a corresponding movement of the air distribution door to direct airflow between the panel (headliner) registers and the floor duct.

Blower Motor

The auxiliary climate control system contains a blower motor which is controlled by the blower motor switch on the auxiliary climate control assembly.

Control Assembly

The auxiliary climate control system control consists of temperature, blower speed and air distribution mode. The auxiliary climate control assembly is mounted in the overhead console.

Heater Core

The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the auxiliary heater core and evaporator core housing.

Evaporator Core

The evaporator core is an aluminum plate/fin type and is located in the auxiliary heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and then moves out of the evaporator core through the evaporator core outlet tube. When the A/C compressor is operating, air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins.

Thermostatic Expansion Valve

Note. An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan bracket connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve (TXV). This filter must be inspected before a new TXV is installed.

The TXV restricts the flow of refrigerant from the high pressure side of the refrigerant system and separates the low pressure and high pressure sides of the auxiliary refrigerant system. Refrigerant entering the auxiliary evaporator core passes through the TXV. A temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.

Scheme 207

REMOVAL AND INSTALLATION

1. Remove the bolts and the rear cargo management cover.
2. Remove the screw and pin-type retainer and remove the rear cargo management system.
3. Remove the access panel.
4. Remove the vent tube.
5. Disconnect the blower motor electrical connector.
6. Remove the 3 blower motor screws.
7. Remove the blower motor.
8. Remove the blower motor retainer.
9. Remove the blower motor wheel.
10. To install, reverse the removal procedure.

Scheme 208

1. Remove the switch bezel.
2. Disconnect the power lock switch electrical connector.
3. Remove the access panel.
4. Disconnect the auxiliary blower motor resistor electrical connector.
5. Remove the 2 auxiliary blower motor resistor screws.
6. Remove the auxiliary blower motor resistor.
7. To install, reverse the removal procedure.

Scheme 209

1. Remove the overhead console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the 2 screws.
3. Remove the bezel.
4. Remove the auxiliary climate control assembly.
5. To install, reverse the removal procedure.

Auxiliary Evaporator Outlet and Inlet Line - Front

Material

Scheme 210

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Disconnect the front auxiliary evaporator inlet line front fitting. Discard the O-ring seals.
3. Remove the RH running board. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) article.
4. Disconnect the front auxiliary evaporator outlet line front fitting.
5. Remove the RH rear wheel.
6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
7. Remove the 3 auxiliary line bracket nuts. To install, tighten to 6 Nm (53 lb-in).
8. Remove the 3 auxiliary line bracket bolts. To install, tighten to 6 Nm (53 lb-in).
9. Remove the 6 auxiliary line brackets.
10. Remove the front auxiliary evaporator outlet and inlet lines.
11. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Auxiliary Evaporator Outlet and Inlet Line - Rear

Material

Scheme 211

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the spare tire.
4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers.
5. Remove the spare tire carrier.
6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
8. Remove the auxiliary line bracket nut. To install, tighten to 6 Nm (53 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary evaporator outlet line.
11. Remove the rear auxiliary evaporator inlet line. Discard the thermostatic expansion valve (TXV) filter.
12. To install, reverse the removal procedure. Install new O-ring seals. Install a new TXV filter. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
13. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 212

Scheme 213

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Release the 2 heater hose clamps and disconnect the heater hoses.
4. Remove the rear quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
5. Remove the 2 auxiliary line floorpan bracket nuts.
6. Remove the 4 line bracket screws and the line bracket.
7. Disconnect the auxiliary harness electrical connector.
8. Remove the 2 auxiliary housing bolts and auxiliary housing nut. To install, tighten to 6 Nm (53 lb-in).
9. Disconnect the 2 auxiliary actuator electrical connectors.
10. Remove the 3 auxiliary mode door actuator screws.
11. Remove the auxiliary mode door actuator.
12. Remove the 3 auxiliary temperature blend door actuator screws.
13. Remove the auxiliary temperature blend door actuator.
14. Remove the 4 heater core cover screws.
15. Remove the heater core cover.
16. Disconnect the 2 heater core hose clamps.
17. Remove the auxiliary heater core.
18. To install, reverse the removal procedure. Lubricate the coolant hoses with plain water only if needed.
19. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Auxiliary Heater Core and Evaporator Core Housing

Material

Scheme 214

Scheme 215

Note. Clean and lubricate the coolant hoses with plain water only if needed.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
4. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
5. Detach the headliner duct from the auxiliary climate control housing.
6. Remove the auxiliary evaporator inlet and outlet line fitting nuts. Discard the O-ring seals. Discard the thermostatic expansion valve (TXV) filter. To install, tighten to 8 Nm (71 lb-in).
7. Release the heater hose clamps and disconnect the heater hoses. After disconnecting the heater hoses, allow any residual coolant to drain from the auxiliary heater core to avoid coolant spilling inside the passenger compartment.
8. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary heater core and evaporator core housing bolts. To install, tighten to 6 Nm (53 lb-in).
10. Remove the auxiliary heater core and evaporator core housing nut. To install, tighten to 6 Nm (53 lb-in).
11. Disconnect the auxiliary harness electrical connector.
12. Remove the auxiliary heater core and evaporator core housing.
13. To install, reverse the removal procedure. Clean and lubricate the coolant hoses with plain water only if needed. Install new O-ring seals. Install a new TXV filter. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
14. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
15. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 216

1. Remove the RH running board. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the RH rear wheel.
4. Release the front auxiliary heater line front clamps and disconnect the heater hoses.
5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses.
6. Remove the 3 auxiliary line bracket nuts. To install, tighten to 6 Nm (53 lb-in).
7. Remove the 3 auxiliary line bracket bolts. To install, tighten to 6 Nm (53 lb-in).
8. Remove the 6 auxiliary line brackets.
9. Remove the front auxiliary heater outlet and inlet lines.
10. To install, reverse the removal procedure.
11. Fill the engine cooling system, For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 217

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the spare tire.
4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers.
5. Remove the spare tire carrier.
6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses.
7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses.
8. Remove the 2 auxiliary line bracket nuts. To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary heater outlet line.
11. Remove the rear auxiliary heater inlet line.
12. To install, reverse the removal procedure.
13. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 218

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
3. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 auxiliary heater core and evaporator core housing bolts. To install, tighten to 6 Nm (53 lb-in).
5. Remove the auxiliary heater core and evaporator core housing nut. To install, tighten to 6 Nm (53 lb-in).
6. Disconnect the auxiliary harness electrical connector.
7. Disconnect the auxiliary mode door actuator electrical connector.
8. Remove the 3 auxiliary mode door actuator screws.
9. Remove the auxiliary mode door actuator.
10. To install, reverse the removal procedure.

Scheme 219

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
3. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 auxiliary heater core and evaporator core housing bolts. To install, tighten to 6 Nm (53 lb-in).
5. Remove auxiliary heater core and evaporator core housing nut. To install, tighten to 6 Nm (53 lb-in).
6. Disconnect the auxiliary harness electrical connector.
7. Disconnect the auxiliary temperature blend door actuator electrical connector.
8. Remove the 3 auxiliary temperature blend door actuator screws.
9. Remove the auxiliary temperature blend door actuator.
10. To install, reverse the removal procedure.

Material

Scheme 220

Note. An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan bracket connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve (TXV). This filter must be inspected before a new TXV is installed.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the D-pillar trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
3. Detach the rear portion of the LH quarter trim panel and position away from the TXV.
4. Remove the 4 clips and the TXV cover.
5. Remove the insulating tape. Retain the tape for reuse.
6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the evaporator outlet line.
7. Disconnect the 2 TXV fittings and remove the TXV. Discard the O-ring seals. To install, tighten to 23 Nm (17 lb-ft).
8. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

See also:
• INSTRUMENT PANEL AND CONSOLE
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• EXTERIOR TRIM AND ORNAMENTATION
• JACKING AND LIFTING
• ENGINE COOLING
• INTERIOR TRIM AND ORNAMENTATION