How do you replace a rear heater box in a 2003 Ford Expedition?

Question

How do you replace a rear heater box in a 2003 Ford Expedition?

Answer 1

Auxiliary Climate Control Housing    

Removal and Installation

Drain the engine coolant. For additional information, refer to Section 303-03.

Recover the refrigerant. For additional information, refer to Section 412-00.

Remove the RH quarter trim panel. For additional information, refer to Section 501-05.

Detach the upper air duct from the auxiliary housing.

Disconnect the drain hose.

Remove the nuts and disconnect the auxiliary evaporator outlet and inlet line fittings.

Discard the O-ring seals.

Remove the bolts and the auxiliary line bracket.

Disconnect the heater hoses.

Using suitable tools, clamp off the heater hoses.

Disconnect the heater hoses.

Disconnect the blower motor and blower motor resistor electrical connectors.

Disconnect the electrical actuator electrical connectors.

Remove the bolt.

Remove the bolt and the auxiliary climate control housing.

To install, reverse the removal procedure.

Install new O-ring seals.

Clean and lubricate the coolant hoses with plain water only if needed.

Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Section 412-00.

Fill the engine coolant level. For additional information, refer to Section 303-03.

Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412-00.