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Re: heater core removal in 92 ford taurus
You'll have to remove the dash in layers. The heater box is the last thing you actually get to. It's not a fun job. It's a very time consuming job. I believe "book" time on that job is around 8 hours. Even guys like me that have done these before take longer that what "book" times is.
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I have done this in an '86 Sable which is very similar. It is a very long process (an 8-10 hour job as listed by Ford Service).
Basically, you are going to have to drain the coolant, evacuate the air conditioning system of refrigerant, disconnect the battery, disable the airbag system (if applicable), remove the panel under the steering wheel, drop the steering column, remove the dashboard, cut the A/C plenum and remove the A/C evaporator, remove the heater core.
This is a very big job for a do-it-yourselfer, but it has been done. I highly recommend buying a Chilton manual or borrowing from a library. Some libraries have the Chilton manuals available for viewing online.
Good luck from Detroit, MI
P.S.: When I did all that on my Sable, it turned out that the heater core wasn't leaking... the hose clamps were loose and a hose was shooting coolant through the firewall into the heater plenum! D'oh!
First disconnect steering knucke under dash. Remove dash assembly to reveal heater/AC case. Disconnect heater hoses from engine compartment. Discharge and capture AC refrigerant. Remove heater case ,replace heater core . re-assemble .
This is a very big job, You must remove the complete dash assembly, then remove the heater box assembly , then replace the heater core and reassmble everything that was removed to gain access to the heater core.
you have to remove the dash. i suggest you go to an auto parts store and buy an after market tech manual. by the way everything under that smooth dash is sharp and give yourself a good weekend to complete. GOOD LUCK.
The heater core can only be removed after the dash board is removed from the vehicle. To remove the dash board the steering column needs to be dropped down or better yet also removed from the car. In addition to these two items being removed, the evaporator box in the engine compartment may need to be removed to provide access to the plenum box mounting nuts. Once the plenum is exposed, the box needs to be pulled back toward the rear of the vehicle and the core is removed through the top. It may seem like a tremendous undertaking, but it's the proper way to do it. Cutting holes in the plenum box or attempting to seal the core with these "magic" additives you pour into your radiator will only create more and larger problems for you in the future. The only short cut I can recommend, is instead of draining your radiator, pull one of the hoses off the core stubs and turn it back to the other stub while you're performing the repair. This will save you some time by not having to refill the entire system and bleed the air from the engine block. The Ford repair manual states 7.1 hours for the complete job. A good mechanic who stays at the repair can do the entire jobs in about three hours. TAKE YOUR TIME AND DON'T FORCE ANY COMPONENTS OR ATTEMPT TO BEND OR PRY THEM OUT OF YOUR WAY. Good Luck
This is a big job which involves discharging and removing parts of the A/C system as well as removing parts of the dash. I had the core done on a 94 Sable years ago and it was a very labor intensive and expensive job. Here are some instructions I found for a 94 Taurus which should be the same thing or similiar, but I don't guarantee that. Please note that these instructions were not tested by me and may contain errors or be incomplete in some way. For example "remove instrument panel" sounds simple but in reality is a process in itself requiring the removal of many screws. Naturally you would have to recharge the A/C and refill the coolant when done.
1. Remove instrument panel and lay it on front seat. 2. Remove A/C evaporator housing as outlined. 3. Remove vacuum source line from heater dash panel seal (18529). 4. Remove heater dash panel seal from heater core tubes (refer to Heater Case Assembly). 5. Remove four heater core access cover retaining screws and remove heater core cover (18B300) from A/C evaporator housing. 6. Lift heater core and seals from A/C evaporator housing. ________________________________________________ Installation
1. Transfer three foam core seals to new heater core. 2. Install heater core and seals into A/C evaporator housing. 3. Position heater core cover on A/C evaporator housing. Install four retaining screws. 4. Install heater dash panel seal on heater core tubes. 5. Install vacuum source line through heater dash panel seal. 6. Install A/C evaporator housing into vehicle as outlined.
7. Reinstall dashboard components.