I was wondering if anyone could give me some pointers on how to change the heater plenum on a 1997 ford explorer. I have no idea where to start with this. Any ideas would be greatly appreciated.

Thanks in advance,
David

 

Well first you remove the intstrument panel.. here is the directions for remove and install on that.

Instrument Panel
Removal

Remove the steering column; refer to Section 211-04 .
Disconnect the brake pedal position (BPP) switch electrical connector.

Remove the LH and RH cowl side trim panels.
Remove the pushpin.

Disconnect the electrical connectors and the ground wires on the RH cowl panel.

Disconnect the power distribution box from the bracket and position aside.

Disconnect the bulkhead wiring harness connectors from inside the engine compartment.
Loosen the bolts.
Disconnect the electrical connectors.

Pull the bulkhead electrical connector handle to disconnect the harness.

Remove the passenger side air bag module (044A74) ; refer to Section 501-20B .
Disconnect the blend door actuator electrical connector.

Disconnect the climate control vacuum harness connector.

Disconnect the radio antenna cable in-line connector.

Raise the glove compartment.
Press the glove compartment release tabs inward while raising the glove compartment.

Remove the instrument panel defroster opening grille.

Remove the instrument panel cowl top bolts.

If equipped, remove the upper series floor console; refer to Console—Floor, Upper Series .
Remove the instrument panel brace bolt.

Remove the windshield side garnish mouldings.

Remove the RH instrument panel cowl side bolt.

Remove the instrument panel fuse panel door.

Remove the LH instrument panel cowl side bolts.

Position the instrument panel away from the dash panel.
Disconnect the instrument panel to body harness.
Loosen the bolt.
Disconnect the harness.

NOTE: Two technicians are required to perform this step.

Remove the instrument panel.
If necessary, transfer components to the new instrument panel.
Installation

NOTE: Two technicians are required to perform this step.

Position the instrument panel.
Connect the instrument panel to body harness.
Connect the harness.
Tighten the bolt.

Align and install the instrument panel.
Install the LH instrument panel cowl side bolts.

Install the RH instrument panel cowl side bolt.

Install the instrument panel cowl top bolts.

Install the instrument panel defroster opening grille.

Install the instrument panel fuse panel door.

Install the instrument panel brace bolt.

If equipped, install the floor console; refer to Console—Floor, Upper Series .
Install the windshield side garnish mouldings.

Lower the glove compartment.
Press the glove compartment release tabs inward while pulling downward on the glove compartment.

Connect the radio antenna cable in-line connector.

Connect the climate control vacuum harness connector.

Connect the blend door actuator electrical connector.

Install the passenger side air bag module ; refer to Section 501-20B .
Connect the electrical connectors and the ground wires on the RH cowl panel.

Position the bulkhead electrical connector handle.

Install the bulkhead wiring harness connectors.
Connect the electrical connectors.
Tighten the bolts.

Install the power distribution box onto the power distribution box bracket.

Install the LH and RH cowl side trim panels.
Install the pushpin.

Connect the brake pedal position (BPP) switch electrical connector.

Install the steering column; refer to Section 211-04 .




Then you drain the radiator and disconnect the heater hoses..

Then you remove the evaporator assembly..

Recover the refrigerant. For additional information, refer to Section 412-00 .
Disconnect the A/C cycling switch (19E561).

Disconnect the electrical connectors.
Disconnect the A/C blower motor electrical connector.
Disconnect the A/C blower motor resistor electrical connector.

Disconnect the heater core (18476).
Disconnect the heater water hoses (18472).
Disconnect the heater water control valve vacuum hose.

Position the speed control servo (9C735) aside.
Remove the (A) bolt and disconnect the (B) servo electrical connector.
Position the speed control servo aside.

Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside.

Disconnect the A/C manifold and tube (19D734) from the suction accumulator/drier. For additional information, refer to Section 412-00 .

Disconnect the condenser to evaporator tube (19835). For additional information, refer to Section 412-00 .

Disconnect the (B) A/C system vacuum harness and the (A) A/C evaporator housing mounting nut inside the vehicle.

Remove the A/C evaporator housing (19850).
Remove the three underhood and one underdash nuts.
Lift the A/C evaporator housing out of the vehicle.

Then remove plenum assembly..

Remove the nuts and remove the plenum chamber

Hope this helps..