First off, let me say that whoever designed the A/C system on my Explorer Limited, didnt' have a better idea.

OK, I know my evaporator is bad. Intake piping cracked and was so bad that it snapped off when I was loosening the nuts.

Here's my problem. According to the Ford replacement procedure, the Evaporator service cover needs to be removed. Unfortunately, there are no specifics as to how that magic trick is done.

Somehow, I managed to get all the bolts, and one nut off the cover.....all but one. I took it to my local repair guy, and he's telling me it's an eight hour job to do the rest of the work, because they have to go up under the dash, remove the heater core, etc.

The cover bolt in question, is at the very bottom, near the fire wall. The difficult part is that the inner wheel well is in the way. There is no way I can get a wrench on the nut to remove it.

So, my questions are these.

Is there a better way to go at this?:

Are there any other bolts I need to worry about?

One thought I had was taking my Dremel and cut an access hole to get to that bolt. Replacing the panel I cut out when completed....leaving me a way back in, in case I need it.

I'd appreciate any advice anyone has. Somewhere, there must be someone who's gone through all this.