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Eric
Eric, Automotive Repair Shop Manager
Category: Ford
Satisfied Customers: 24682
Experience:  Automotive Repair Shop Manager, Technician
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how to replace a heater core on a 1999 ford f150 xlt

Resolved Question:

how to replace a heater core on a 1999 ford f150 xlt
Submitted: 4 years ago.
Category: Ford
Expert:  Eric replied 4 years ago.

Hi,

 

You will need to remove the instrument panel in order to replace the heater core:

 

instrument panel:

 

Click image to see an enlarged view

Fig. Fig. 2 Remove the bulkhead electrical connectors from inside the engine compartment



Click image to see an enlarged view

Fig. Fig. 3 Remove the audio unit ground and the GEM/CTM ground bolts



Click image to see an enlarged view

Fig. Fig. 4 Remove the instrument panel bolts through the steering column opening



Click image to see an enlarged view

Fig. Fig. 5 Remove the passenger side ground bolt



Click image to see an enlarged view

Fig. Fig. 6 Detach the passenger side instrument panel main harness connectors



Click image to see an enlarged view

Fig. Fig. 7 Remove the instrument panel bolt on the relay bracket



Click image to see an enlarged view

Fig. Fig. 8 Remove the instrument panel bolts through the passenger side air bag module opening



Click image to see an enlarged view

Fig. Fig. 9 Remove the instrument panel reinforcement bolt below the driver's side corner of the glove compartment



Click image to see an enlarged view

Fig. Fig. 10 Position the carpet aside and loosen the instrument panel floor brace



Click image to see an enlarged view

Fig. Fig. 11 Remove the passenger side instrument panel cowl side nut





Click image to see an enlarged view

Fig. Fig. 13 Remove the cowl panel mounting bolts



Click image to see an enlarged view

Fig. Fig. 14 Remove the instrument panel

  1. Move the seat fully rearward.
  2. If equipped with a manual transmission, place the transmission into second gear.
  3. Disarm the Air bag system by disconnecting battery & waiting 10 minutes
  4. Disconnect the negative battery cable.
  5. Position the battery junction box aside.
  6. Remove the bulkhead electrical connectors from inside the engine compartment.
  7. Remove the bulkhead electrical connector insulator.
  8. Unclip the bulkhead electrical connectors from the dash panel.
  9. If equipped, remove the center console.
  10. Remove the lower instrument panel steering column cover.
  11. If equipped, remove the valance panel.
  12. Detach the restraint control module (RCM) electrical connector.
  13. Detach the electronic blend door actuator electrical connector.
  14. Detach the climate control head vacuum harness connector.
  15. Remove the driver's side and passenger side scuff plates.
  16. Position the driver's side and passenger side door weatherstrip seals aside.
  17. Remove the driver's side and passenger side A-pillar lower trim panels.
  18. If equipped, remove the alternative fuel control module (AFCM).

 

The AFCM is attached with velcro.

  1. Remove the four covers, the four screws and remove the passenger side assist handle.
  2. Remove the driver's side and passenger side windshield side garnish mouldings.
  3. Detach the brake pedal position switch electrical connector.
  4. If equipped, detach the clutch pedal position switch.
  5. On Expedition and Navigator models, detach the adjustable pedal motor connector, if equipped.
  6. Remove the audio unit ground and the GEM/CTM ground bolts.
  7. Detach the driver's side instrument panel main wiring harness connectors.
  8. Remove the instrument panel steering column opening cover reinforcement.
  9. Detach the air bag sliding contact electrical connectors and the anti-theft sensor electrical connector.
  10. Detach the remaining electrical connectors on the steering column.
  11. If equipped, detach the transmission range indicator from the steering column.
  12. Lower the steering column.
  13. Remove the instrument panel bolts through the steering column opening.
  14. Remove the instrument panel reinforcement bolt below the driver's side corner of the cigar lighter and power point.
  15. Detach the inertia fuel shutoff switch electrical connector.
  16. Remove the passenger side ground bolt.
  17. If equipped, detach the air suspension wiring harness electrical connector.
  18. Detach the passenger side instrument panel main harness connectors.
  19. Release all the wiring harness locators from the cowl side panel.
  20. Detach the climate control wiring harness connector.
  21. Remove the radio chassis. Refer to .
  22. Disconnect the three cable locators from the lower instrument panel channel and remove the audio unit antenna lead-in cable from the instrument panel.
  23. Remove the instrument panel relay cover.
  24. Remove the instrument panel bolt on the relay bracket.
  25. Remove the glove compartment.



CAUTION Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with minimal chance of injury. Place a live air bag on a bench or other surface with the trim cover up.

  1. Remove the passenger side air bag module.
  2. Remove the instrument panel bolts through the passenger side air bag module opening.
  3. Remove the instrument panel reinforcement bolt below the driver's side corner of the glove compartment.
  4. Position the carpet aside and loosen the instrument panel floor brace.
  5. Remove the passenger side instrument panel cowl side nut.
  6. Remove the driver's side instrument panel cowl side nut.
  7. On all models except for Navigator, remove the instrument panel cowl top bolts.
  8. On Navigator, remove the defroster grille assembly.
  9. Remove the cowl panel mounting bolts.

 

Two people are required to perform this step.

  1. Remove the instrument panel.

 

To install:

Two people are required to perform this step.

  1. Align and position the instrument panel with the clips in the sheet metal.
  2. Install the instrument panel cowl top bolts.
  3. Install the instrument panel mounting bolts.
  4. Install the covers.
  5. Install the driver's side instrument panel cowl side nut.
  6. Install the passenger side instrument panel cowl side nut.

 

To prevent any squeaks or rattles, install and tighten the upper instrument panel floor brace bolt first, then tighten the floor brace bolts and nut.

  1. Install the upper instrument panel floor brace bolt.
  2. Install the instrument panel reinforcement bolt below the driver's side corner of the glove compartment.
  3. Install the instrument panel bolt on the relay bracket.
  4. Install the instrument panel bolts through the passenger side air bag module opening.

 

Install the passenger side bolt first.


CAUTION Never probe the connectors on the air bags. Doing so may result in air bag deployment, which could result in personal injury. Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with a minimal chance of injury.

  1. Install the passenger side air bag module.
  2. Install the glove compartment.
  3. Install the instrument panel relay cover.
  4. If equipped, attach the autolamp sensor electrical connector.
  5. Install the instrument panel relay cover.
  6. Position the audio unit antenna lead-in cable into the instrument panel.
  7. Connect the cable locators between the instrument panel channel and the audio unit end of the cable.
  8. Install the radio chassis. Refer to .
  9. Attach the climate control wiring harness connector.
  10. Attach the passenger side instrument panel main harness connectors.
  11. If equipped, attach the load leveling control suspension wiring harness electrical connector.
  12. Install the passenger side ground bolts.
  13. Attach the inertia fuel shutoff switch electrical connector.
  14. Install the instrument panel reinforcement bolt below the driver's side corner of the cigar lighter and power point.
  15. Install the instrument panel bolts through the steering column opening.
  16. Position the steering column.
  17. Install the four steering column support nuts.
  18. If equipped, connect the transmission range indicator to the steering column.
  19. Attach the remaining electrical connectors on the steering column.
  20. Attach the air bag sliding contact electrical connectors and the anti-theft sensor electrical connector.
  21. Install the instrument panel steering column opening cover reinforcement.
  22. Attach the driver's side instrument panel main wiring harness connectors.
  23. Connect the audio unit ground and the GEM/CTM ground bolts.
  24. If equipped, connect the CPP switch.
  25. Attach the BPP switch electrical connector.
  26. Install the driver's side and passenger side windshield side garnish mouldings.
  27. Install the passenger side assist handle.
  28. If equipped, install the alternative fuel control module (AFCM).
  29. Attach the electrical connnector.
  30. Install the driver's side and passenger side A-pillar lower trim panels.
  31. Install the driver's side and passenger side door weatherstrip seals.
  32. Install the driver's side and passenger side scuff plates.
  33. Attach the climate control head vacuum harness connector.
  34. Attach the electronic blend door actuator electrical connector.
  35. Attach the RCM electrical connector, engage the locking tab and insert the wiring harness locator.
  36. If equipped, install the valance panel.
  37. Install the lower instrument panel steering column cover.
  38. Clip the bulkhead electrical connectors into the dash panel.
  39. Install the bulkhead electrical connector insulator.
  40. Attach the bulkhead electrical connectors from inside the engine compartment.
  41. Install the battery junction box into the mounting tabs.
  42. Connect the negative battery cable.

 

heater core:

 


Click image to see an enlarged view

Fig. Fig. 2 Remove the A/C plenum demister screw and remove the A/C plenum demister adapter



Click image to see an enlarged view

Fig. Fig. 3 Disconnect the vacuum line



Click image to see an enlarged view

Fig. Fig. 4 Remove the heater core bracket



Click image to see an enlarged view

Fig. Fig. 5 Remove the 13 retaining screws and remove the plenum chamber top



Click image to see an enlarged view

Fig. Fig. 6 Remove the heater core


CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the battery.
  2. Drain and recycle the engine coolant.
  3. Remove the instrument panel. Refer to .
  4. Compress the holding tabs and disconnect the heater water hoses at the heater core.
  5. Remove the A/C plenum demister screw and remove the A/C plenum demister adapter.
  6. Disconnect the vacuum line.
  7. Remove the heater core bracket.
  8. Remove the 13 retaining screws and remove the plenum chamber top.
  9. Remove the blend door assembly from the case.
  10. Remove the heater core.To install:
  11. The installation is the reverse of the removal.
Customer: replied 4 years ago.
would u happen to know what the going rate is if a shop does the work i have the new heater core already thanks
Expert:  Eric replied 4 years ago.

Hi,

 

Well labor rates vary from shop to shop, each according to its needs to meet overhead.

But expect to be charge 8hrs labor for the job. With labor rates varying from $60 per hour on low end and $130 per hour on high end, expect to pay between $800 to $1100 parts and labor for a shop to do the work.

 

It can be done at home in a weekend. Nothing very difficult, just time consuming, and at times hard on the back as you are working in and under the dash to remove it.

Eric, Automotive Repair Shop Manager
Category: Ford
Satisfied Customers: 24682
Experience: Automotive Repair Shop Manager, Technician
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