2nd Gen Non-Engine/Transmission heater core replacement problems

[JAmos]

I just bought a 97 and i'm trying to change the heater core. I have the whole dash tore out and I'm still trying to get the stinking thing out. Does anyone have any tips for making this chore easier?



Jordan

 

[DieselDoghouse]

I think this one ranks as the "back surgery' of our trucks. There is no easy approach to get it out. The heater boxes are one-piece, unlike import trucks. Once you have the dash pulled up or removed you gotta find all the anchors to the firewall and remove, separate the A/C lines, the heater hoses, the vacuum control lines and the temperature (blend door) cable, then the thingy should come right out!! For the work involved you might wanta replace the evaporator at the same time. Check it real good - any sediment from sucking dirt/leaves down the heater duct will eventually rot the evaporator. When you open the heaterbox, clean it well, check the condensate drain port. Reassemble and 'bench test' all the dampers before reinstall - they like to pop out of place!!. To reinstall, reverse the prior 2 days work!! Good luck.

 

[JAmos]

OK-first thing has anyone shot the designer for the heater system? If not I volunteer.



The haynes manual said to disconnect the a/c but I was hoping to be clever enough to avoid that. I think my truck is going to have an a/c leak-I'm not towing it somewhere to add to the frustration.



Can I put the two plastic halves all the way back together on the metal frame and then install it as a unit? Or does that create more problems when reconnecting every single type of connection and air ducting?



Thanks, Jordan