Engine/Transmission (1994 - 1998) Need Help Replacing Heater Core....

[Ingoldsby]

Need help and/or any useful suggestions on replacing heater core in 1996 W 2500 with standard transmission. without having to dismantle the entire truck... can you avoid having to discharge AC lines? Thanks in advance... .

 

[Tom C]

I can't remember exactly the procedure I used but I can tell you the WHOLE dash will be removed. Almost...

If memory serves me... There are only a few screws (along windshield) and a couple of bolts (at kick panel just up from bottom of dash) that hold the dash in. Once the screws are removed and the bolts loosened the dash will roll (pivoting on the bolts) away from the windshield. Only thing is... you have to unhook all the electric connectors and speedo cable in order to get it to roll out. I remember taking the radio out, speedo out, disconnecting the vacuum line for the a/c & heater control's, loosening the steering wheel, etc.

Once you have all that stuff unhooked and the dash rolled out. Now you can work on the air/heater box that is bolted to the firewall. I think all the bolts holding that, you access from the engine bay. I think you'll have to remove the computer to get to one or two.

I was able to do it without unhooking my a/c but I remember having to bend the lines a little to do it. Be careful, they are fragile.

I was able to tilt the heater box out under the dash just enough to get the heater core out (in comes out the top :{). Had to bend those lines a little also. It's a real PITA #@$%!!!! even with the dash tilted out it only leaves enough room to look past the dash with one eye ball with your head pasted against the windshield

Then you get to hope the new one doesn't leak :--)

Good luck

Tom

 

[The patriot]

I saw an article on this in one if the issues... .

 

[JAmos]

I did mine without disconnecting the a/c, but had to carefully bend the lines a bit till it came out. Oh and my new core is starting to leak on its first b-day



Jordan

 

[hsmith]

Just did mine this last week. Better to recover the R134a and disconnect the lines. I can't imagine doing this with the as still connected.

Radio, speedo do not need to be removed as there is no speedo cable.

Vacuum harness connector at lower left center can be accessed with knee bolster removed. Drop steering column. Two electrical connectors at right side along with antenna cable to unplug. Remove screws along windshield, remove kick panels, loosen bolts at lower sides where the dash will be slotted to allow rotation. I lift the dash off the right side and pull it away, allowing you to reach behind and dicsonnect the temp door cable. Then pull it away and prop it up.

Two screws on the inside upper area, the ones under the hood can be accessed easily, though the ecm has to be removed. Then get the whole air box out of the truck so you can do a proper job.

I replaced my evaporator as well along with all the weatherstripping at all the doors and openings.

Probably a three hour job, but I do this for a living too.

 

[Tom C]

Radio, speedo do not need to be removed as there is no speedo cable.

If there is no speedo cable (I can't remember it been a couple of years) basically unhook any wires connected to the back of the dash.

It helped me to remove the radio. Leaves a big whole to reach through when working behind the dash.

Lifting the dash off the right side bolt and swinging it back was also helpful.

 

[The patriot]

Probably a three hour job, but I do this for a living too.

Man, I sure wish you were closer... ...

My mechanic wants $1200 to do this.

 

[RHARVEY]

From the article that Joe wrote in issue 46 I think or maybe it was 44... anyway the only wires were the ground wires... Seems to me all the other stuff stayed connected.

I also will be doing this job tomorrow. . I ordered the core from Advantage Dodge... Didnt want to take chances with the other brands



Rick

 

[hsmith]

You have got to be kidding. $350 labor is good money for this job. Like I said, I can do it in about three hours, but charge more like six. This is doing it the right way with the air box completely out of the truck and on the work bench.

Use OE core also, as after market sometimes is more a universal part.

Removing the radio would probably help with the temp blend door cable. I will try that the next time.

 

[Bill Lins]

hsmith, where are you located?

 

[hsmith]

Bill, I am on Lake LBJ, 60 miles west of Austin and 90 north of San Antonio

 

[RHARVEY]

Did the heater core in the 99 this past Saturday from Joe's article... Well written instructions execpt for the fact that he did the job I believe on an automatic truck. We removed the shifters and the little console around the shifter. Only real big issue that we had was getting those floating studs back thru the firewall. . oh yea we were working on a truck with twin turbos. . Just a wee bit more involved.

Like Joe said... you can just clear the roll in the dash with the core tubes but it does clear. We used the stock OEM unit from Dodge. .

All in all it wasnt that bad of a job.



Rick

 

[Joseph Donnelly]

I changed the heater core on a 97 5 speed truck (no console) for the TDR article.

 

[Neibe]

I changed the heater core on a 97 5 speed truck (no console) for the TDR article.

Do you know what issue?

 

[CSnyder]

2 hours and 40 minutes is my shop record after doing about 30 of them for customers.

 

[Joseph Donnelly]

TDR Issue 46, p. 12