Section 12-03A: Air Conditioning System, Manual A/C-Heater | 1996 F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual |
NOTE: Before replacing any A/C evaporator core (19860) within the warranty for suspected refrigerant leaks, it is mandatory that an on-vehicle leak test be performed. Refer to Section 12-00.
| Description | Tool Number |
|---|---|
| Spring Lock Coupling Disconnect Tool Set | T84L-19623-B |
Removal
NOTE: Cap all open refrigerant lines and components to prevent entry of dirt and moisture into the A/C system.
Discharge refrigerant system following recommended service procedures. Observe all safety precautions. Refer to Section 12-00.
Disconnect electrical connector from A/C cycling switch (19E561) on side of suction accumulator/drier (19C836).
Remove A/C cycling switch from suction accumulator/drier.
Disconnect A/C manifold and tube (19D734) from suction accumulator/drier. Use a backup wrench to loosen fitting. Cap evaporator to compressor suction line (19867) and suction accumulator/drier to prevent entry of dirt and excess moisture.
Using Spring Lock Coupling Disconnect Tool Set T84L-19623-B, disconnect condenser to evaporator tube (19835) from A/C evaporator core. Cap condenser to evaporator tube to prevent entry of dirt and excess moisture.
In passenger compartment, remove one screw attaching A/C evaporator housing (19850).
Remove one nut retaining MAP sensor bracket to the upper left corner of A/C evaporator case (19897).
Remove spring clip holding MAP sensor to housing (on all gas engines). Put MAP sensor aside.
Remove one nut retaining upper left corner of A/C evaporator case to dash panel (01610).
Remove six screws attaching left A/C evaporator case cover (19B735) to A/C evaporator case.
Remove left A/C evaporator case cover from A/C evaporator case.
Remove two screws attaching suction accumulator/drier to A/C evaporator housing.
Remove A/C evaporator core and suction accumulator/drier from A/C evaporator case.
Installation
Install A/C evaporator core into A/C evaporator case.
Position A/C evaporator case cover to A/C evaporator case. Install six screws to attach A/C evaporator case cover to A/C evaporator case along flange.
Install one nut to retain upper left corner of A/C evaporator case to dash panel.
Install one spring clip to rib on A/C evaporator case and push into position.
Install one nut to retain upper left corner of MAP sensor bracket (gas engines) to the upper left corner of A/C evaporator case.
In passenger compartment, install one screw to attach lower edge of the heater air plenum chamber (18471) and bottom of the A/C evaporator case to dash panel.
Remove cap from condenser to evaporator tube connection and install a new A/C evaporator core orifice (19D990) in the tube.
Using new O-ring lubricated with clean refrigerant oil, connect condenser to evaporator tube to A/C evaporator core. Push spring lock coupling until it snaps secure. Pull back to make sure connection is completed.
Add 88.7ml (3 ounces) of clean refrigerant oil to a new suction accumulator/drier to compensate for oil lost in replacement of A/C evaporator core.
Using a new O-ring lubricated with clean refrigerant oil, connect suction accumulator/drier to A/C evaporator core.
Install A/C accumulator bracket (19D607) (two screws). Tighten fitting to 21-27 Nm (15-20 lb-ft). Use a backup wrench on suction accumulator/drier to prevent component damage.
Connect suction accumulator/drier to the A/C evaporator housing with two screws.
Using a new O-ring lubricated with clean refrigerant oil, connect A/C manifold and tube to suction accumulator/drier. Use a backup wrench to prevent component damage.
Using a new O-ring lubricated with clean refrigerant oil, install A/C cycling switch on suction accumulator/drier nipple.
Connect electrical connector to A/C cycling switch.
Leak test, evacuate and charge system following recommended procedures. Refer to Section 12-00. Observe all safety precautions.
Check system for proper operation.