Heater Core / Blend Door Replacement (How To Guide With Pictures)
 

<!-- / icon and title --><!-- message --><!-- google_ad_section_start -->I'd like to thank those that have taken time to write much information about heater core and blend door replacement. I decided to tackle this job myself and I found it to be easier than what I had expected. The time involved was fairly significant, but the overall difficulty of the job is something that anyone with a good socket set and assortment of other basic tools can tackle... saving hundreds of dollars in the process!

Pending on your year model there could be a couple of steps that could be differed a little. The document below opens with MS WORD and can be printed out and taken with you to your truck during repairs.

Here it is... http://nator.net/files/Heater Core Replacement.doc

Hope It Helps!

You are awesome - thanks.

Your Welcome .... I have not gotten this far yet! ... I'm still removing screws and wires... But should be in the plenum tomorrow ....

Good Luck and Thanks Again!

Excellent job of documenting the procedure. Nice photos and illustrations.

Thanks for the help! I just got done with mine. Took about 10 hours. I used this post as well as

https://www.ford-trucks.com/forums/5...ml#post4102926

I also changed my instrument panel lights that have been out for years!

It sure would have been more difficult if I hadn't found this forum.

P.S. I didn't take my entire dash out! Which meant I didn't disconnect alot of unnecessary stuff.

Man this is great !!!! Really appreciate the step by step. I will be starting this today and it looks like it should go pretty good. (Ha! Ha!)

You too, huh? I just drove 350 miles north to pick up a friend - and with this cold spell I had no heat for the entire trip. It made the drive, and will make the drive back, today, interesting.

I moved to south Florida for a reason - and that reason is failing me; I guess moving as far south as I could go still didn't get me out of having to fix the blend door... ;)

I'm starting on my heater core tonight... this is going to suck.

Take your time and it should go ok. It was bolted together so you can unbolt it. Let us know how it goes.

The most expensive tool in your box is "impatience"

Aight it's done! This guide was PRICELESS! I would never have been able to do this myself without it. There were some minor variations between some of the pics and my truck but nothing crazy.

Replaced heater core, upper and lower hose, thermostat, and flushed the cooling system. Also replaced all my instrument cluster light bulbs while I was in there since they were going out!

Took about 15 hours to do everything :/ ... didn't set a speed record but it is all done and no leaks or issues so far!


Thanks again for the guide!

Thanks for the pictures with the instructions. My friend has a '99 with the door stuck in the cool position. He had been quoted $1500 to repair it "properly". From looking at the picture above #38 instruction showing what the door looked like and where it was positioned we decided to drill a 1/4" hole just to the right of the triangular protrusion next to your word "cut". I then stuck a long thin screwdriver through the hole, located the foam strips and the door itself. With some gentle nudging, it unstuck and opened to the heat position. A piece of black electrical tape over the hole finished the "repair". Cost 0$ Without your picture this would not have been possible. Again, many thanks!

My Ford dealership would have fixed it "properly" for about $600.00