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Heater Core Replacement Problem


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Tigerclaw78
User

Feb 14, 2011, 4:34 PM

Post #1 of 25 (5920 views)
Heater Core Replacement Problem Sign In

Hello, I have a problem I'm hoping to get some help with. I'm in the process of replacing the heater core on my 1995 Ford Ranger 2.3, I almost have the dash removed except for a large bundle of wires on the left side that appears to go through the firewall. I'm not sure if i need a special tool to remove these wires or if i'm missing something. Any advice would be appreciated.


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Feb 15, 2011, 6:58 AM

Post #2 of 25 (5892 views)
Re:95 Ranger, Heater Core Replacement Problem Sign In

Not ignoring you just don't know exactly where you are caught up with wires. If you can't get far enough with these wires still there then you have to look for a plug to undo for this so called bundle of wires? If this is necessary and wires are going thru the firewall the plug might be underhood - can't say.

Is this bundle going to a fuse box? Then the fuse box may just drop out of your way. Many heater core replacements get VERY involved in dash parts with all it's stuff. Most wiring connections do not require specialty tools but many use a bail or perhaps you pinch some items like some child proof caps for assorted things. Can take a boatload of little wrenches and sockets for stuff that you must have already noticed if you are almost there.

I'm betting you are attempting this yourself because you've been told some outrageous price to have it done and some of these things can command many hours of labor and as you know just the core itself isn't that expensive.

Couldn't find any vehicle specific tools required to do this job so you have to keep looking.

If you want some exacting instructions with diagrams and graphics buy 1 year subscription to ALLDATA which is currently under $30 bucks for just one vehicle. I don't own a master edition to cover many vehicles to tell you more than I could find surfing around myself which you are doing. If someone here doesn't have the specific info you may need to buy that information as now I think you are stuck with this part way done shops are not going to want to finish this for you now.

Another trick if available to you is to go to a pull your own junkyard and see if you can find one all torn apart and view what left of a carcass of the vehicle which should include Explorers.

Good luck. Hope someone here has more specific info, I don't,

T



re-tired
Veteran / Moderator
re-tired profile image

Feb 15, 2011, 8:43 AM

Post #3 of 25 (5883 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Wiring should not be a problem
*
**
***



REMOVAL & INSTALLATION


1991-94 Models

See Figures 1 to 7



Fig. Fig. 1: Exploded view of the 1991-94 heater core assembly
  1. Disconnect the negative battery cable. Allow the engine to cool down. Drain the cooling system to a level below the heater core fittings on the firewall.



CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.




Fig. Fig. 2: From inside the engine compartment, disconnect the heater hoses from the core fittings ...
  1. Disconnect the heater hoses from the heater core tubes and plug hoses.
  2. In the passenger compartment, remove the four screws attaching the heater core access cover to the plenum assembly and remove the access cover.





Fig. Fig. 3: ... then, in the passenger compartment, remove the under dash cover retaining screws ...



Fig. Fig. 4: ... and allow the cover to drop down. If necessary, you can remove the cover if it is in your way



Fig. Fig. 5: Remove the heater core access panel attaching screws ...



Fig. Fig. 6: ... then remove the cover by pulling downward and straight back to disengage the drain tube (arrow)
  1. Pull the heater core rearward and down, removing it from the plenum assembly.





Fig. Fig. 7: Pull the heater core rearward and down to remove it from the plenum assembly
To install:
  1. Position the heater core and seal in the plenum assembly.
  2. Install the heater core access cover to the plenum assembly and secure with four screws.
  3. Install the heater hoses to the heater core tubes at the dash panel in the engine compartment. Do not over-tighten hose clamps.
  4. Check the coolant level and add coolant as required. Connect the negative battery cable.
  5. Start the engine and check the system for coolant leaks.


1991-99 Models

See Figure 8



Fig. Fig. 8: Exploded view of the blower motor housing and the heater air plenum assemblies
  1. Disconnect the negative battery cable. Allow the engine to cool down. Drain the cooling system to a level below the heater core fittings on the firewall.



CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the heater hoses from the heater core tubes and plug hoses.
  2. Remove the five nuts that secure the blower motor housing to the firewall.
  3. Pull the housing away from the firewall. Disconnect any wire harness plugs which inhibit the housing.
  4. Remove the remaining nuts which secure the heater air plenum (inside the passenger compartment) to the firewall.
  5. In the passenger compartment, remove the instrument panel. Refer to Body & Trim .
  6. Pull the heater air plenum rearward from the firewall and remove it from the vehicle.
  7. Remove the heater core from the heater air plenum.
  8. Inspect all air seals on the components and firewall and replace any that are damaged.


To install:
  1. Install the heater core into the air plenum chamber.
  2. Position the heater air plenum against the firewall from the passenger compartment.
  3. Under the hood, install the plenum retaining nuts.
  4. Install the blower motor housing to the firewall and install the attaching nuts.
  5. Connect the heater hoses to the heater core tubes at the dash panel in the engine compartment. Do not over-tighten the hose clamps.
  6. Install the instrument panel.
  7. Check the coolant level and add coolant as required. Connect the negative battery cable.
  8. Start the engine and check the system for coolant leaks.



LIFE'S SHORT GO FISH


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 9:30 AM

Post #4 of 25 (5880 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

That's strange RT. Those instructions are conflicting with Alldata that states the dash has to be removed.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



re-tired
Veteran / Moderator
re-tired profile image

Feb 15, 2011, 12:32 PM

Post #5 of 25 (5872 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

I dunno , I would hate to give incorrect advise . I can't recall pulling a dash on a ranger. Perhaps you or a tech you know can relate first hand knowlege . If so please post correction . ANYBODY got verification either way . BTW I've never seen ALLDATA to be wrong.


LIFE'S SHORT GO FISH


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 2:34 PM

Post #6 of 25 (5869 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Removal and Installation
  1. Allow the engine to cool. Following all safety precautions and using a thick cloth, turn radiator cap slowly to the first stop. Step back while pressure is released. When the pressure has been released, tighten the radiator cap on the radiator.
  2. Disconnect the heater water hoses from the heater core and plug the heater water hoses.
  3. In the passenger compartment, remove the instrument panel.
  4. Remove heater air plenum chamber. See: Housing assembly HVAC
  5. Remove heater core from heater air plenum chamber.
For installation, follow removal procedures in reverse order.

Heater Core Replace B
6.3



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tigerclaw78
User

Feb 15, 2011, 2:53 PM

Post #7 of 25 (5864 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Thanks for all the info guys. You are correct about the crazy price quote they wanted 750 dollars to do it, core only cost 45. From my understanding 95 and later rangers are the ones that require dash removal before that they don't. So if I read right there is no special tool to remove this connector it must be some sort of child proofing that has got me stumped it is the large bundle of wires that come out below the fuse box.


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 3:17 PM

Post #8 of 25 (5859 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

There will be a connector for it somewhere, probably branches into many connectors.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tigerclaw78
User

Feb 15, 2011, 3:34 PM

Post #9 of 25 (5854 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

its the place where all the branches connect into one to go through the firewall into the fusebox i assume. I'm working on posting a pic of it


Tigerclaw78
User

Feb 15, 2011, 3:46 PM

Post #10 of 25 (5851 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

how do i post pictures?


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 4:04 PM

Post #11 of 25 (5846 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

The best way is to use a photo hosting side and post the image link here and the picture will show up. I use Photobucket.com



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Feb 15, 2011, 4:12 PM

Post #12 of 25 (5842 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Sorry about that tiger - I've had a heck of a time if my own pics but if you can even put a link to where it's posted I can usually make it show up from the link if that's all you can do. Ex: Here's a 95 Ranger.......



See that was nothing because it wasn't my ownCrazy

T



Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 4:39 PM

Post #13 of 25 (5834 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Haha........... don't take any picture posting advice from Tom. he hasn't figured out how to do it himself...........LOL


If you upload your picture to a hosting site, they provide the code that has to be pasted here to make the picture show up here.

Here is what I paste here



And here is what you see





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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tigerclaw78
User

Feb 15, 2011, 4:45 PM

Post #14 of 25 (5830 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In




Tigerclaw78
User

Feb 15, 2011, 4:46 PM

Post #15 of 25 (5829 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Smile glad that worked thanks guys, not a good picture but hopefully someone will recognize what it is. Those little plastic clips on the right side are what i think is holding it in place and there are three more on the other side. location is under drivers side dash right beside clutch pedal.


(This post was edited by Tigerclaw78 on Feb 15, 2011, 5:00 PM)


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 15, 2011, 5:45 PM

Post #16 of 25 (5814 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

That looks like the PCM but i wouldn't expect it would have to be disconnected to get the dash off. The individual plugs will be removed from the dash side.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tigerclaw78
User

Feb 15, 2011, 5:57 PM

Post #17 of 25 (5810 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Ok i will check that tomorrow. Thanks


Tigerclaw78
User

Feb 16, 2011, 1:48 PM

Post #18 of 25 (5798 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

I checked it again and there are wires running from this connector into the dash I can't see any disconnects on the dash side so i'm back to my original problem it seems


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 16, 2011, 2:12 PM

Post #19 of 25 (5791 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

You seem to be in over your head here. You really need to give this job to a professional. This is only the beginning of the problems you're going to run into.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tigerclaw78
User

Feb 16, 2011, 6:54 PM

Post #20 of 25 (5785 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

If don't know how to help just say so insults not necessary


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 16, 2011, 7:31 PM

Post #21 of 25 (5780 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

I'm just stating the facts as i see them. I don't know any other way to tell you that you shouldn't be attempting this.
Let's face facts. you can't figure out how to disconnect the wires. It's going to get a lot harder.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



(This post was edited by Hammer Time on Feb 16, 2011, 7:32 PM)


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Feb 16, 2011, 11:05 PM

Post #22 of 25 (5775 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Everyone calm down a bit! Tiger - this is a hard job when you are in the trade and I'm not surprised it's frustrating you. Hindsight is 20/20 like they say but it's underway so guys let's help get this job done or why are we here?

True Tiger that if most of us were there would just know where to look after years of busting knuckles and getting burnt. Said first that IDK this job and when I Google the snots out of it came up with mixed info. Not a problem when you know what to look for - got the T-shirt on that.

Hammer - ease up cause as I see it he's stuck now and said in one of many posts on this a shop isn't going to like a part done job at this point so let's show some true color and fix this.

Tiger - there's only so much suggestions anyone can do without being there with many issues this site handles. IDK why this wiring is a problem? What I do know is you have to keep a good mind as you need to put this all back together perfectly or you'll be right back there again. New core may come with swivel necks and orig was fixed. Get that right and before finishing pressure check cooling system even with just air so you know it's good. You can bust a new heater core just installing it! If it won't hold once installed then you can deal with it before putting the whole mess back together.

That's why it cost so much money to do this stuff and I'm sure you understand it now.

Tiger - can you do this without messing with those wires? Is there enough room with them still there if the disconnection of them is so hard to find? I'm not there to see it - you are.

Come on guys - fish or cut bait. Can we help or are we useless for this guy in this jam?

Tom


re-tired
Veteran / Moderator
re-tired profile image

Feb 18, 2011, 7:37 PM

Post #23 of 25 (5755 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

 
OPERATION


The Powertrain Control Module (PCM) performs many functions on your car. The module accepts information from various engine sensors and computes the required fuel flow rate necessary to maintain the correct amount of air/fuel ratio throughout the entire engine operational range.
Based on the information that is received and programmed into the PCM's memory, the PCM generates output signals to control relays, actuators and solenoids. The PCM also sends out a command to the fuel injectors that meters the appropriate quantity of fuel. The module automatically senses and compensates for any changes in altitude when driving your vehicle.
REMOVAL & INSTALLATION


See Figure 1


Fig. Fig. 1: Typical PCM module 491-92 Models

See Figure 2
  1. Disconnect the negative battery cable.
  2. Remove the inside, lower cowl trim panel from the passenger's side of the vehicle to expose the PCM.
  3. Disengage the wiring harness connector from the PCM by loosening the connector retaining bolt, then pulling the connector from the module.
  4. Remove the PCM from the bracket by pulling the unit downward.




Fig. Fig. 2: View of the right-hand kick panel PCM mounting for 491-92 models To install:
  1. Install the PCM in the mounting bracket.
  2. Attach the wiring harness connector to the module, then tighten the connector retaining bolt.
  3. Install the right cowl trim panel.
  4. Connect the negative battery cable.

493-99 Models

See Figures 3 and 4
The module is mounted under the hood on the firewall. On 493-94 models, it is mounted low on the firewall, near the left-hand fender (drivers side). On 495-99 models, it is mounted high on the firewall offset to the right-hand side of center.


Fig. Fig. 3: Exploded view of the firewall PCM mounting for 493-94 models


Fig. Fig. 4: Exploded view of the firewall PCM mounting for 495-99 models
  1. Disconnect the negative battery cable.
  2. Disengage the wiring harness connector from the PCM by loosening the connector retaining bolt, then pulling the connector from the module.
  3. Remove the two nuts and the PCM cover.
  4. Remove the PCM from the bracket by pulling the unit outward.

To install:
  1. Install the PCM in the mounting bracket.
  2. Install the PCM cover and tighten the two nuts.
  3. Attach the wiring harness connector to the module, then tighten the connector retaining bolt.
  4. Connect the negative battery cable.



LIFE'S SHORT GO FISH


Tigerclaw78
User

Feb 27, 2011, 6:14 PM

Post #24 of 25 (5739 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

Hey guys, just thought i'd update everyone on this since i haven't been on here in awhile. I got the heater core job finished last wednesday the truck is running great now with no problems. I want to thank everyone on here that helped with it. cheers


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Mar 2, 2011, 1:06 PM

Post #25 of 25 (5720 views)
Re: Re:95 Ranger, Heater Core Replacement Problem Sign In

God Bless Tiger.

It isn't easy when you have a 1/mil in tools to do this. Thanks for your report of success,

T







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