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Heater Core and Evaporator Replacement
This write up is for Gen2 (1992 -1995) Taurus (and Sable?). I think it also applies to Gen 1 (1989-1991) Taurus & Sable. Online there are videos of “short cuts” which are NOT applicable to these older models – those apparently work on Gen 3 (1996-1999) and younger models. This job is doable by a weekend warrior if one has patience and can understand what is involved. It is going to take 8+ hours, so perhaps spread over a couple of days? So in that regard, I have attempted to provide many pictures so that those with some mechanical inclination can take on the challenge and find success!
What follows in posts here is only a brief sketch of the actual procedure. The details can be found in the pdf file (6 pages). It has some background, tools & materials, parts, job overview and then the procedures. Procedures have been broken down into 14 blocks:
Preliminaries – Must Do Things To Start the Job
Under the Hood
Inside the Taurus: Stupid – Ticky Tacky Stuff
[b][color=#0000ff]Steering Column
Instrument Panels
Speed/Fuel/ Temp
Glove Box Area – Electrical Connections [/color][/b]
Now get dash off – Dash Removal
[b][color=#0000ff]Black Boxes
Heater Core (HC) Removal & installation
Evaporator (optional)
Finishing Touches [/color][/b]- Ready to reinstall
ReinstallationThe “full text” is attached as a pdf file: Steps HC & Evap Replace Post. In order to keep this file as a manageable size, I have limited the text instructions without a lot of discussion. Steps should be read in conjunction with the over 200 pictures that accompany. Blue text above corresponds to the labels on the pictures. There is a picture for nearly every number/lettered step. In fact, there are often more than one picture for each step as I attempted to make this as user (novice) friendly as possible.
The things that I consider to be “crux” issues were things that stopped me for a while as I figured out how to solve them or had to go get tools or parts. Even the best write-ups I found online had significant gaps/areas where the author wrote “I don’t remember!” Hopefully, I’ve filled most of those gaps!
Job Overview
[u]
Dash removal[/u]lThere are 7 bolts that need to be removed to get the dash off. Most are hidden. Also one is going to need to remove the steering column. I have seen write ups that suggest the steering column can be lowered, I guess if one is experienced they could figure out how to do this, I think it is easier to just take out. I think the dash can be partially removed (moved) in a way that saves a BUNCH of electrical disconnects. But hey, go to town with connections if one wishes!
Black Air Duct/Housings Removal
There are bolts on both the inside and outside that hold the black boxes(BBs)/ duct work in place! Outside, in the engine compartment there are 3 nuts on bolts on the boxes that hold this unit in place as well as two A/C Line connectors and two heater hose connections. One exterior bolt is “hidden” under the Accumulator/Drier mounting bracket. On the inside there are 5 bolts/screws and a bracket that hold the unit in place. Two 7/32-in head screws, that are virtually hidden and hard to access, are the last thing before one can free this unit. By this time one is tired and anxious, so knowing the location and unusual bolt head size upfront will save on drags from that can of patience!
Electrical Connections
There are a few electrical connections that will need to be opened:
• just 4 at the blower/black boxes area (accessible once glove box removed),
• 5 at the stereo/lighter area,
• 4 on the steering column,
• 4 on the curved instrument panel trim and
• 3 on the actual gauges panel.The Procedure
What follows is only a brief teaser of pictures of the process. Please see the full write up and the full set of pictures. I have over 80-hours in formatting pictures, cleaning up the written text and importing this mess to the web. I hope someone finds it useful and can take on this repair for them self and save the $600+ most shops quote.
Under the Hood
Ticky Tacky Stuff
Steering Column
Instrument Panels
Speed/Fuel/ Temp
Glove Box Area – Electrical Connections
Dash Removal
- Replies
Here (hopefully) are the files with the complete instructions and the files with all of the pictures!
This whole effort, and posting here, is just one way I can say thanks to those that have helped me along the way. I asked for help on several issues in the middle of this repair and got great responses. Could not have done it without all of the help!
So again, THANK YOU for helping me.
Hopefully some who needs it stumbles on to this info and puts it to good use and that inspires them to “pay forward” with something they know.
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