A/c System General Servicing: Removal & Installation Ford Thunderbird X

ORIFICE TUBE REPLACEMENT - AEROSTAR, BRONCO, EXPLORER

Scheme 9

Scheme 10

Scheme 11

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect liquid line at evaporator.
2. To disconnect liquid line, fit appropriate spring lock coupling clamp on the line. See SPRING LOCK COUPLING CLAMP table. Close clamp and push into opening side of cage to expand garter spring and release female fitting. After garter spring is expanded, pull coupling apart. (Scheme 9)
3. Pour small amount of refrigeration oil into inlet tube to lubricate orifice tube and "O" rings. Attach Orifice Tube Remover/Installer (T83L-19990-A) on the 2 tangs of the orifice tube. (Scheme 10) NOTE: DO NOT twist or rotate orifice tube in evaporator inlet tube pipe, as it may break inside the tube.
4. Hold "T" handle of orifice tube remover/installer to keep it from turning, and rotate the nut downward against inlet line until orifice tube is pulled from inlet tube. If orifice tube breaks in inlet tube, use Broken Orifice Tube Extractor (T83L-19990-B) to remove the orifice tube. (Scheme 11)
5. To remove broken orifice tube, insert screw end of extractor into inlet tube and thread into orifice tube. Rotate extractor nut downward against liquid line and remove orifice tube.
6. If only brass center tube is extracted, insert screw end of extractor into inlet. Screw end of extractor into fixed orifice tube body. Remove tube body from evaporator core line.

SPRING LOCK COUPLING CLAMP

INSTALLATION

1. Ensure replacement orifice tube is same color as that removed. Lubricate "O" rings on orifice tube with clean refrigeration oil. Place orifice tube into orifice tube remover/installer. Insert orifice tube into evaporator inlet tube until orifice tube bottoms against the stop.
2. Remove orifice tube remover/installer. Install liquid on evaporator using a new "O" ring lubricated with refrigeration oil. Pull backward on liquid line to ensure proper seating of the line. Leak test, evacuate and recharge the system. Check system for proper operation.

ORIFICE TUBE R & I - E & F SERIES, RANGER

REMOVAL

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect liquid line at evaporator.
2. To disconnect liquid line, fit appropriate spring lock coupling clamp on the line. See SPRING LOCK COUPLING CLAMP table. Close clamp and push into opening side of cage to expand garter spring and release female fitting. After garter spring is expanded, pull coupling apart. see scheme 16
3. Pour small amount of refrigeration oil into inlet tube to lubricate orifice tube and "O" rings. Attach Orifice Tube Remover/Installer (T83L-19990-A) on the 2 tangs of the orifice tube. see scheme 17 NOTE: DO NOT twist or rotate orifice tube in evaporator inlet tube pipe, as it may break inside the tube.
4. Hold "T" handle of orifice tube remover/installer to keep it from turning, and rotate the nut downward against inlet line until orifice tube is pulled from inlet tube. If orifice tube breaks in inlet tube, use Broken Orifice Tube Extractor (T83L-19990-B) to remove the orifice tube. see scheme 18
5. To remove broken orifice tube, insert screw end of extractor into inlet tube and thread into orifice tube. Rotate extractor nut downward against liquid line and remove orifice tube.
6. If only brass center tube is extracted, insert screw end of extractor into inlet. Screw end of extractor into fixed orifice tube body. Remove tube body from evaporator core line.

1. Ensure replacement orifice tube is same color as that removed. Lubricate "O" rings on orifice tube with clean refrigeration oil. Place orifice tube into orifice tube remover/installer. Insert orifice tube into evaporator inlet tube until orifice tube bottoms against the stop.
2. Remove orifice tube remover/installer. Install liquid on evaporator using a new "O" ring lubricated with refrigeration oil. Pull backward on liquid line to ensure proper seating of the line. Leak test, evacuate and recharge the system. Check system for proper operation.

ORIFICE TUBE R & I - CROWN VIC/GRAN MARQUIS/TWN CAR

1. Orifice tube is located in the evaporator inlet pipe. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect liquid line at evaporator.
2. To disconnect liquid line, fit appropriate spring lock coupling clamp on the line. See SPRING LOCK COUPLING CLAMP table earlier in article. Close clamp and push into opening side of cage to expand garter spring and release female fitting. After garter spring is expanded, pull coupling apart. (Scheme 9)
3. Pour small amount of refrigeration oil into inlet tube to lubricate orifice tube and "O" rings. Attach Orifice Tube Remover/Installer (T83L-19990-A) to 2 tangs on fixed orifice tube. (Scheme 10) NOTE: DO NOT twist or rotate orifice tube in evaporator inlet tube pipe, as it may break inside the tube.
4. Hold "T" handle of orifice tube remover/installer to keep it from turning, and rotate the nut downward against inlet line until orifice tube is pulled from inlet tube. If orifice tube breaks in inlet tube, use Broken Orifice Tube Extractor (T83L-19990-B) to remove the orifice tube.
5. To remove broken orifice tube, insert screw end of extractor into inlet tube and thread into orifice tube. Rotate extractor nut downward against liquid line and remove orifice tube. (Scheme 11)
6. If only brass center tube is extracted, insert screw end of extractor into inlet. Screw end of extractor into fixed orifice tube body. Remove tube body from evaporator core line.

1. Ensure replacement orifice tube is same color as that removed. Lubricate "O" rings on orifice tube with clean refrigeration oil. Place orifice tube into orifice tube remover/installer. Insert orifice tube into evaporator inlet tube until orifice tube bottoms against the stop.
2. Remove orifice tube remover/installer. Install liquid on evaporator using a new "O" ring lubricated with refrigeration oil. Pull backward on liquid line to ensure proper seating of the line. Leak test, evacuate and recharge the system. Check system for proper operation.

1. Orifice tube is located in the line, near the condenser. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect liquid line at condenser.
2. To disconnect liquid line, fit appropriate spring lock coupling clamp on the line. See SPRING LOCK COUPLING CLAMP table earlier in article. Close clamp and push into opening side of cage to expand garter spring and release female fitting. After garter spring is expanded, pull coupling apart. (Scheme 9)
3. Using Orifice Tube Remover/Installer (T83L-19990-A), remove orifice tube from the line. If orifice tube breaks in inlet tube, use Broken Orifice Tube Extractor (T83L-19990-B) to remove the orifice tube.

1. Ensure replacement orifice tube is same color as that removed. Lubricate "O" rings on orifice tube with clean refrigeration oil. Using orifice tube remover/installer, install orifice tube.
2. Reconnect line on condenser using a new "O" ring lubricated with refrigeration oil. Leak test, evacuate and recharge the system. Check system for proper operation.

Scheme 12

Scheme 13

1. Orifice tube is located in condenser-to-evaporator liquid refrigerant line near condenser by the 3 indented notches or circular depression in the line. (Scheme 12)
2. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. To remove liquid line, fit appropriate spring lock coupling clamp on the line. See SPRING LOCK COUPLING CLAMP table earlier in article.
3. Close clamp and push into opening side of cage to expand garter spring and release female fitting. After garter spring is expanded, pull coupling apart. (Scheme 9) Remove liquid line.
4. Locate orifice tube in metal portion of liquid line (3 indented notches or circular depression). (Scheme 12) Note angle positions of liquid line ends for reassembly. Cut a 2 1/2" (63.5 mm) section from tube at orifice location. DO NOT cut closer than 1" (25.4 mm) from start of bend in liquid line. (Scheme 13)
5. Flush out liquid line. Lubricate "O" rings with refrigeration oil. Assemble orifice tube kit on liquid line. (Scheme 13) Ensure replacement orifice tube is the same color as that removed.
6. Ensure flow direction arrow is pointed at evaporator and taper on ferrule is toward the nut. While holding hex of liquid line in a vise, tighten each compression nut to 65-70 ft. lbs. (88-95 N.m).
7. Reconnect line, using a new "O" ring lubricated with refrigeration oil. Leak test, evacuate and recharge the system. Check system for proper operation.