Heating & Ventilation: Removal & Installation Ford Thunderbird XI

Removal and Installation

Note. The following procedure is intended to be used for removal and installation of the steel heater tube assembly.

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1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204560) .
3. Remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION & FILTERING»(ref-204567) .
4. Remove the air cleaner outlet pipe. .
5. Release the clamps and disconnect the heater hoses.
6. Disconnect the heater hose quick-disconnect couplings.
7. Disconnect the heater hose quick-disconnect coupling.
8. Remove the rear heater hose assembly bracket bolt.
9. Remove the front heater hose assembly bracket bolt.
10. Remove the bolts and position the hydraulic fan reservoir aside.
11. Remove the three bolts and position the wire harness bracket aside.
12. Release the clamp and disconnect the heater hose.
13. Remove the steel heater tube assembly.
14. If necessary, disengage the crimps and remove the bracket.
15. If necessary, remove the rivet and the bracket.
16. If removing the dual heater control valve heater hoses or the auxiliary coolant flow pump heater hoses, disconnect the upper radiator hose and remove the heater hose(s).
17. To install, reverse the removal procedure. If the heater tube assembly has been separated, install a new crimp bracket. If the heater tube assembly has been separated, install the tube bracket and rivet. Clean and lubricate the coolant hoses with plain water only, if needed.
18. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-204581) .
2. Remove the passenger side floor duct. For additional information, refer to «AIR DISTRIBUTION & FILTERING»(ref-204567) .
3. Remove the screws and remove the cover.
4. Disconnect the connector and remove the blower motor.
5. Remove the wheel from the blower motor. Remove the push clip. Remove the wheel from the blower motor.
6. To install, reverse the removal procedure.

All vehicles

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1. Depower the supplemental restraint system (SRS). For additional information, refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-150664-S20598976392002112000000) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
3. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204560) .
4. Remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION & FILTERING»(ref-204567) .
5. Disconnect the heater hose assembly from the heater core. 3.0L vehicles
6. Disconnect the differential pressure feedback (DFPE) sensor. Disconnect the vacuum hoses. Disconnect the electrical connector.
7. Remove the wire harness retaining nuts and position the wiring harness aside.
8. Remove the two harness bracket retaining bolts from the RH cylinder head and position the bracket aside. All vehicles
9. Remove the bolt and disconnect the manifold and tube assembly from the thermostatic expansion valve. Discard the O-ring seals.
10. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-204638) .
11. Disconnect the connector located on the top of the evaporator core housing.
12. Detach and position the wiring harness aside.
13. Remove the cowl top attachment bolt.
14. Remove the evaporator housing attachment bolt.
15. Remove the nut and washer assembly retaining the evaporator housing to the bulkhead.
16. Remove the nut and washer assembly retaining the evaporator housing to the bulkhead.
17. Remove the nut and washer assembly retaining the evaporator housing to the bulkhead.
18. Remove the evaporator core housing.
19. To install, reverse the removal procedure. Install new O-ring seals. Clean and lubricate the coolant hoses with plain water only if needed.
20. Fill the engine coolant level. For additional information, refer to «ENGINE COOLING»(ref-204560) .
21. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .

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1. Remove the evaporator core housing. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING»(ref-204569-S36325797162005111300000) .
2. Remove the evaporator core housing to air inlet housing screws.
3. Disengage the clip and separate the evaporator core housing from the air inlet housing.
4. Disconnect the evaporator core housing electrical connectors and position the wire harness aside.
5. Remove the gasket.
6. Remove the nine screws, disengage the clip and separate the heater core and evaporator core housing.
7. Remove the screws.
8. Remove the heater core.
9. Remove the heater core tube gasket.
10. To install, reverse the removal procedure.