AC system removal
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Elder User
Joined: Feb 2008
Posts: 999
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From: Davison, Mi.
AC system removal
I want to get rid of the AC on my Highboy. It doesnt work, most of the components are long gone and I don't want to work around the HUGE!!! box in the engine compartment.
What does it take to remove the AC box and put just a heater in it? Anyone ever cut an AC box down to contain just the heater system?
What does it take to remove the AC box and put just a heater in it? Anyone ever cut an AC box down to contain just the heater system?
Laughing Gas
Joined: Jul 2002
Posts: 843
Likes: 1
From: USA
I did the reverse process in my truck. That huge box in the engine compartment contains both the heater core and the blower motor. You will have to contend with a huge hole in the bulkhead(firewall) after you get everything removed. Your best bet would be to hit the salvage yards and locate a donor truck that has just the heater system. While you're there, get the dash so you don't have the A/C vents anymore and also the control panel and cables and all the duct work behind the dash. There is a cover plate on the drivers side of your cab, inside, which is a manual fresh air vent for use in the summer. Lots of work.
Laughing Gas
Joined: Dec 2007
Posts: 796
Likes: 1
From: Minnesota
I did this on my truck like Gary said except like you want. I went to the local u-pull $25 for the whole assembly under the dash. Then switched out the drivers side metal cover with the vent down by your feet. For the hole in the fire wall I cut a piece of sheet metal to cover it with holes cut for the heater motor, etc. I used nut plates in the inside piece, so now if I want to replace the heater core, blower motor, the whole plate comes right off and easy access. I kept the a/c dash, just cut metal plates and painted them to match with nutplates. Makes nice access holes if you need to work on something. You will also need the controller part from a doner truck. I got the high output heater also. Probably some of those in Mi. Took some time and wiring. I actually had an engine fire. So had to replace everything anyway. I used to repair DC-10's and 747 sheet metal and make the parts frome blue prints so have some fabricating skills. Now China does that. But thats another story.
Posting Guru
Joined: Mar 2005
Posts: 1,004
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From: In the Middle
I did this on my truck like Gary said except like you want. I went to the local u-pull $25 for the whole assembly under the dash. Then switched out the drivers side metal cover with the vent down by your feet. For the hole in the fire wall I cut a piece of sheet metal to cover it with holes cut for the heater motor, etc. I used nut plates in the inside piece, so now if I want to replace the heater core, blower motor, the whole plate comes right off and easy access. I kept the a/c dash, just cut metal plates and painted them to match with nutplates. Makes nice access holes if you need to work on something. You will also need the controller part from a doner truck. I got the high output heater also. Probably some of those in Mi. Took some time and wiring. I actually had an engine fire. So had to replace everything anyway. I used to repair DC-10's and 747 sheet metal and make the parts frome blue prints so have some fabricating skills. Now China does that. But thats another story.
Laughing Gas
Joined: Dec 2007
Posts: 796
Likes: 1
From: Minnesota
Here is some pics I took today for the after. 
The ball things are my plastic vacuum canisters I got from the junk yard. No rust worries
The ball things are my plastic vacuum canisters I got from the junk yard. No rust worries
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Laughing Gas
Joined: Dec 2007
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From: Minnesota
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From: In the Middle
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YIKES! That sucks about the engine fire, but the finished product now looks awesome! Thanks for the pics, I really like how nice it turned out. I may try to duplicate that with hopes of achieving the same great results.
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YIKES! That sucks about the engine fire, but the finished product now looks awesome! Thanks for the pics, I really like how nice it turned out. I may try to duplicate that with hopes of achieving the same great results.
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Posting Guru
Joined: Jun 2002
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From: where the deer and antelo
Dirt racer has it covered. The turbo and exhaust on my cummins didn't like the AC box so one of them had to go. The ac lost. I did the same thing to my truck, except I had the heater donor truck sitting in the yard. I cut the metal from the donor truck fire wall so other than color miss match it looks factory. My only mistake was I ended up riviting the piece in the fire wall about 1/4 inch too far to the right and it left a bit of an air gap where the heater and cold air intake meet. A bit of weatherstrip foam took care of the problem.
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