Heater Core Replacement
2002 Ford F350
Heater Core Replacement Procedures
2002 Ford F350
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Heater Core Replacement
1. Disconnect both battery cables.
2. Drain the radiator.
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Warning: Wait at least 2 minutes after disconnecting the battery cables to allow the air bag supplemental energy source to discharge completely. Observe responsible safety procedures as you proceed.
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3. Remove the upper and lower trim panels that surround the steering column.
4. Remove the fuse box cover.
5. Detach the hood and parking brake release handles.
6. Remove the floor duct cover panel.
7. Remove the lower instrument panel steering column cover
8. Remove the door scuff plates and cowl side trim panels on both the driver and passenger sides.
9. Disconnect the electrical connector from the brake switch.
10. Disconnect all electrical connections along the floor and lower right side of the passenger's foot rest area.
11.Remove the instrument panel steering column opening cover reinforcement.
12. If your vehicle has one, disconnect the transmission shift range indicator from the steering column.
13. With the transmission in Park, carefully lower the steering column.
14. Remove the instrument panel relay cover.
15. Disconnect the auto lamp sensor connector (if your vehicle has one)
16. Remove the passenger side air bag module.
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Warning: Follow all safety precautions for safe handling of air bag modules.
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17. Remove the passenger side assist handle.
18. Remove the passenger side windshield garnish molding.
19. Remove the nine instrument panel bolts located at strategic locations around the instrument panel.
20. Remove the two instrument panel retaining nuts from the bolts at the bottom corners of the instrument panel.
21. Remove the RH instrument panel floor brace.
22. With the assistance of a helper, pull on both sides of the dash and move it about 4 inches away from the firewall. (If the dashboard does not yet seem to be free, look for other bolts, screws, wires, lines, etc. that might still need to be released in order to move the dash. Additional factory options or after market add-on equipment may have electrical or mechanical connections that will have to be disconnected.) Once all obstructions have been resolved, carefully slide the entire dash assembly straight back away from the firewall approximately 4 inches.
23. When the dash has cleared the supporting guide rails on each side, carefully continue to move the passenger side away from the firewall while allowing the driver side to pivot about an imaginary axis approximately 4 inches from the firewall (in essence, rotate the entire dashboard like a door that is hinged on the driver side and opens on the passenger side. As you SLOWLY swing the passenger side of the dash away from the firewall, carefully watch for any wires/connectors, tubing, radio antenna or other items that may also need to be moved or disconnected to allow greater freedom of movement.
24. From the engine compartment disconnect the heater hoses from the heater core tubes using a heater hose disconnect tool.
25. Remove the A/C plenum demister adapter,
26. Remove the vacuum line adjacent to the heater core bracket.
27. Remove the heater core bracket.
28. Remove the top cover of the heater plenum.
29. Remove the blend door assembly.
30. Remove the heater core.
31 Install the new heater core and reverse the procedures.
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