dashboard removal
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Joined: Jan 2004
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dashboard removal
I have a '99 Expy and I need to remove the dash to replace the heater core. Can anybody give me some ideas on what the best way to go about doing this is? Do I really need to remove the whole dash?
Logistics Pro
Joined: Oct 2000
Posts: 3,960
Likes: 5
From: All over Texas
WOW!
According to my manual, yes, you do have to remove the entire instrument panel (and then some) to get the core out.
Good Luck!
Instrument Panel
Removal
CAUTION:
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
1. If equipped with power seats, move the seat fully rearward.
2. If equipped with adjustable pedal system, move the pedals to the full forward position.
3. WARNING:
To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute.
Disconnect the battery cables.
4. Position the battery junction box (BJB) power distribution box aside.
l Release the mounting tabs.
5. Remove the bulkhead electrical connectors from inside the engine compartment.
1 Loosen the bolts.
2 Disconnect the bulkhead electrical connectors.
6. Remove the bulkhead electrical connector insulator.
7. Unclip the bulkhead electrical connectors from the dash panel.
8. If equipped, remove the front floor console.
9. Remove the lower instrument panel steering column cover.
10. Remove the valance panel.
l Remove the two pin-type retainers and release the expander clip.
11. Disconnect the restraint control module (RCM) electrical connector.
1 Release the locking tab.
2 Disconnect the RCM electrical connector.
l Release the wiring harness locators.
12. Disconnect the electronic blend door actuator electrical connector.
l Release the wiring harness locators.
13. Disconnect the climate control head vacuum harness connector.
14. Remove the LH and RH scuff plates.
15. Position the LH and RH door weatherstrip seals aside.
16. Remove the LH and RH A-pillar lower trim panels.
17. Remove the RH and LH assist handles (31406).
1 Remove the covers and the bolts.
2 Remove the assist handles.
18. Note:
Release the top attachments by pulling inboard first and then upward to release the lower hook.
Remove the LH and RH windshield side garnish mouldings (03598).
l If equipped, on the LH windshield garnish moulding, disconnect the cellular phone hands-free microphone electrical connector.
19. Disconnect the brake pedal position (BPP) switch electrical connector.
l Release the wiring harness locator.
20. If equipped, disconnect the adjustable pedal motor electrical connector.
21. If equipped, disconnect the adjustable pedal motor harness electrical connector.
22. Remove the (A) radio ground and the (B) generic electronic module (GEM)/central timer module (CTM) ground bolts.
23. Disconnect the LH instrument panel main wiring harness connectors and bulkhead connector.
1 Loosen the bolt.
2 Disconnect the electrical connectors and the bulkhead connector.
l Release the main wiring harness locators.
24. Remove the instrument panel steering column opening cover reinforcement (04502).
1 Remove the nuts.
2 Remove the instrument panel steering column opening cover reinforcement.
25. Disconnect the (A) air bag sliding contact electrical connectors and the (B) anti-theft sensor electrical connector.
26. Disconnect the remaining electrical connectors on the steering column.
27. Disconnect the transmission range indicator from the steering column.
1 Remove the bolt.
2 Disconnect the cable.
28. Lower the steering column (3C529).
1 Remove the nuts.
2 Lower the steering column.
29. Remove the instrument panel bolts through the steering column opening.
30. Remove the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.
31. Disconnect the inertia fuel shutoff switch electrical connector.
32. Remove the RH ground bolt.
33. If equipped, disconnect the air suspension switch electrical connector.
34. Disconnect the RH instrument panel main harness connectors.
l Release all the wiring harness locators from the cowl side panel.
35. Disconnect the blower motor electrical connector.
36. If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
37. Disconnect the in-line antenna connector.
38. Remove the instrument panel relay cover.
1 Remove the instrument panel relay cover.
2 If equipped, disconnect the autolamp sensor electrical connector.
3 If equipped, disconnect the sunload sensor electrical connector.
39. Remove the glove compartment. For additional information, refer to «Glove Compartment» in this section.
40. WARNING:
Always wear safety glasses when removing and handling an air bag.
WARNING:
Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with minimal chance of injury.
WARNING:
Place a live air bag on a bench or other surface with the trim cover up.
Remove the passenger side air bag module (044A74).
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the passenger side air bag module.
41. Remove the instrument panel bolts through the passenger side air bag module opening.
42. Remove the instrument panel bolt on the relay bracket.
43. Remove the instrument panel reinforcement bolt below the LH corner of the glove compartment.
44. Note:
Position the carpet aside.
Loosen the instrument panel floor brace.
1 Remove the upper instrument panel floor brace bolt.
2 Loosen the instrument panel brace bolts and nut.
45. Remove the RH instrument panel cowl side nut.
46. Remove the LH instrument panel cowl side nut.
47. On Expedition, remove the instrument panel cowl top bolts.
1 Remove the covers.
2 Remove the bolts.
48. On Navigator, remove the instrument panel defroster grille assembly.
49. On Navigator, remove the instrument panel cowl top bolts.
50. Note:
This step requires an assistant.
Note:
Two bullet connectors secure the instrument panel to the bulkhead.
Remove the instrument panel.
According to my manual, yes, you do have to remove the entire instrument panel (and then some) to get the core out.
Good Luck!
Instrument Panel
Removal
CAUTION:
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
1. If equipped with power seats, move the seat fully rearward.
2. If equipped with adjustable pedal system, move the pedals to the full forward position.
3. WARNING:
To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute.
Disconnect the battery cables.
4. Position the battery junction box (BJB) power distribution box aside.
l Release the mounting tabs.
5. Remove the bulkhead electrical connectors from inside the engine compartment.
1 Loosen the bolts.
2 Disconnect the bulkhead electrical connectors.
6. Remove the bulkhead electrical connector insulator.
7. Unclip the bulkhead electrical connectors from the dash panel.
8. If equipped, remove the front floor console.
9. Remove the lower instrument panel steering column cover.
10. Remove the valance panel.
l Remove the two pin-type retainers and release the expander clip.
11. Disconnect the restraint control module (RCM) electrical connector.
1 Release the locking tab.
2 Disconnect the RCM electrical connector.
l Release the wiring harness locators.
12. Disconnect the electronic blend door actuator electrical connector.
l Release the wiring harness locators.
13. Disconnect the climate control head vacuum harness connector.
14. Remove the LH and RH scuff plates.
15. Position the LH and RH door weatherstrip seals aside.
16. Remove the LH and RH A-pillar lower trim panels.
17. Remove the RH and LH assist handles (31406).
1 Remove the covers and the bolts.
2 Remove the assist handles.
18. Note:
Release the top attachments by pulling inboard first and then upward to release the lower hook.
Remove the LH and RH windshield side garnish mouldings (03598).
l If equipped, on the LH windshield garnish moulding, disconnect the cellular phone hands-free microphone electrical connector.
19. Disconnect the brake pedal position (BPP) switch electrical connector.
l Release the wiring harness locator.
20. If equipped, disconnect the adjustable pedal motor electrical connector.
21. If equipped, disconnect the adjustable pedal motor harness electrical connector.
22. Remove the (A) radio ground and the (B) generic electronic module (GEM)/central timer module (CTM) ground bolts.
23. Disconnect the LH instrument panel main wiring harness connectors and bulkhead connector.
1 Loosen the bolt.
2 Disconnect the electrical connectors and the bulkhead connector.
l Release the main wiring harness locators.
24. Remove the instrument panel steering column opening cover reinforcement (04502).
1 Remove the nuts.
2 Remove the instrument panel steering column opening cover reinforcement.
25. Disconnect the (A) air bag sliding contact electrical connectors and the (B) anti-theft sensor electrical connector.
26. Disconnect the remaining electrical connectors on the steering column.
27. Disconnect the transmission range indicator from the steering column.
1 Remove the bolt.
2 Disconnect the cable.
28. Lower the steering column (3C529).
1 Remove the nuts.
2 Lower the steering column.
29. Remove the instrument panel bolts through the steering column opening.
30. Remove the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.
31. Disconnect the inertia fuel shutoff switch electrical connector.
32. Remove the RH ground bolt.
33. If equipped, disconnect the air suspension switch electrical connector.
34. Disconnect the RH instrument panel main harness connectors.
l Release all the wiring harness locators from the cowl side panel.
35. Disconnect the blower motor electrical connector.
36. If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
37. Disconnect the in-line antenna connector.
38. Remove the instrument panel relay cover.
1 Remove the instrument panel relay cover.
2 If equipped, disconnect the autolamp sensor electrical connector.
3 If equipped, disconnect the sunload sensor electrical connector.
39. Remove the glove compartment. For additional information, refer to «Glove Compartment» in this section.
40. WARNING:
Always wear safety glasses when removing and handling an air bag.
WARNING:
Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with minimal chance of injury.
WARNING:
Place a live air bag on a bench or other surface with the trim cover up.
Remove the passenger side air bag module (044A74).
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the passenger side air bag module.
41. Remove the instrument panel bolts through the passenger side air bag module opening.
42. Remove the instrument panel bolt on the relay bracket.
43. Remove the instrument panel reinforcement bolt below the LH corner of the glove compartment.
44. Note:
Position the carpet aside.
Loosen the instrument panel floor brace.
1 Remove the upper instrument panel floor brace bolt.
2 Loosen the instrument panel brace bolts and nut.
45. Remove the RH instrument panel cowl side nut.
46. Remove the LH instrument panel cowl side nut.
47. On Expedition, remove the instrument panel cowl top bolts.
1 Remove the covers.
2 Remove the bolts.
48. On Navigator, remove the instrument panel defroster grille assembly.
49. On Navigator, remove the instrument panel cowl top bolts.
50. Note:
This step requires an assistant.
Note:
Two bullet connectors secure the instrument panel to the bulkhead.
Remove the instrument panel.
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Johnny Mo
1997 - 2006 Expedition & Navigator
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Feb 17, 2002 08:27 AM
