This procedure replaces the AC expansion valve (TXV) on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine, requiring AC system evacuation, evaporator core access, and refrigerant recharge.

Warnings

Tools required

Parts

• AC expansion valve (TXV) × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• R-134a refrigerant × 1 — Per system capacity
• PAG 46 compressor oil × 1 — Per manufacturer spec
• Cabin air filter × 1 — Use OEM specification

Preparation

1. Verify the expansion valve is the actual problem (symptoms include inconsistent cooling, icing at evaporator, or superheat/subcool readings out of specification)
2. Park vehicle on level surface and set parking brake
3. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
4. Allow engine and AC system to cool completely if recently operated
5. Verify AC recovery machine is properly calibrated and refrigerant tanks are not full
6. Place protective covers over front seats and floor to prevent damage during dash work

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to service ports. Identify refrigerant type using identifier tool to confirm R-134a. Recover all refrigerant from system according to machine instructions. Record amount of refrigerant and oil recovered. Allow recovery until system reaches and holds vacuum for proper measurement.
2. 2

   Remove lower dash panel and cabin air filter
   Remove lower dash panel on passenger side by releasing retaining clips and removing fasteners. Remove glove box by squeezing sides and lowering past stops. Remove cabin air filter housing cover and extract cabin air filter. This provides initial access to evaporator housing.
3. 3

   Disconnect AC lines at firewall
   From engine compartment, locate AC liquid and suction lines at firewall near passenger side. Use flare nut wrenches to disconnect both lines from evaporator connections. Cap open lines immediately to prevent moisture intrusion. Remove and discard old O-rings from both connections.
   ⚠Small amounts of residual refrigerant or oil may be present. Wear safety glasses and gloves.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Remove evaporator housing cover
   From inside vehicle, locate and remove all screws securing the evaporator housing cover (typically 6-8 screws). Carefully separate cover from housing. The expansion valve is mounted on the evaporator inlet tube inside this housing.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
5. 5

   Remove expansion valve
   Locate expansion valve attached to evaporator inlet tube. Note orientation and position of thermal bulb (sensing element) clamped to suction line. Remove thermal bulb clamp. Disconnect electrical connector from expansion valve if equipped with electronic control. Remove expansion valve mounting fasteners and carefully extract valve from evaporator tubes. Remove and discard old O-rings.
   ⚠Do not bend or kink the thermal bulb capillary tube if valve is sensing-bulb type. This will destroy valve calibration.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
6. 6

   Install new expansion valve
   Install new O-rings on evaporator tube connections, lubricating with fresh PAG 46 oil. Position new expansion valve onto evaporator tubes in same orientation as original. Ensure thermal bulb will contact suction line properly. Thread mounting fasteners and torque to specification. Reconnect electrical connector if equipped.
   ℹ️Install valve quickly to minimize moisture exposure. Keep new valve sealed until ready to install.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
7. 7

   Secure thermal bulb
   Position thermal bulb (sensing element) against suction line in proper location (typically at 4 or 8 o'clock position on horizontal tube). Secure with new clamp, ensuring good thermal contact. Ensure capillary tube is not kinked or under tension.
8. 8

   Reinstall evaporator housing cover
   Verify all connections inside housing are secure. Position evaporator housing cover and install all mounting screws. Torque screws to specification in a cross pattern to ensure even seating and proper seal.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
9. 9

   Reconnect AC lines at firewall
   Install new O-rings on both AC line connections, lubricating with fresh PAG 46 oil. Connect liquid and suction lines to evaporator fittings at firewall. Hand-tighten first to ensure proper threading, then torque to specification using flare nut wrenches.
   ⚠Do not over-torque AC fittings as this can damage aluminum components or crack fittings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Evacuate AC system
    Connect vacuum pump or AC machine in evacuation mode to service ports. Evacuate system to minimum 29 inches Hg (98 kPa) vacuum. Hold vacuum for minimum 30 minutes to verify no leaks and remove all moisture. If vacuum does not hold, locate and repair leak before proceeding.
    ℹ️Proper evacuation is critical. Moisture in system will freeze at expansion valve and cause intermittent operation or component damage.
11. 11

    Recharge AC system
    With system still under vacuum, add correct amount of PAG 46 oil to system (add amount removed plus 1 oz for new expansion valve). Charge system with R-134a refrigerant to specified capacity (approximately 1.75-2.0 lbs for F-150, verify on underhood label). Use AC machine to ensure accurate charge by weight.
12. 12

    Reinstall interior components
    Install new cabin air filter. Reinstall cabin air filter housing cover. Reinstall glove box assembly and lower dash panel, ensuring all clips and fasteners are properly secured.
13. 13

    Reconnect battery and test system
    Reconnect negative battery cable. Start engine and set AC to maximum cool with recirculation mode. Allow system to run for 10 minutes. Verify compressor engages, no unusual noises occur, and both low and high side pressures are within specification. Check for proper cooling at vents (should be 38-42°F with 80-90°F ambient).

Reassembly

1. Verify all dash panels and trim pieces are securely fastened with no rattles
2. Ensure glove box operates smoothly and latches properly
3. Check that all interior fasteners are installed and nothing was left loose
4. Verify battery cable is tight and battery voltage is normal

Verification

• Confirm AC blows cold air (vent temperature 38-42°F with 80-90°F ambient temperature)
• Verify compressor cycles properly and system maintains consistent temperature
• Check for refrigerant leaks at all AC line connections using electronic leak detector or UV dye
• Monitor AC performance over 15-20 minute drive cycle to ensure no icing or temperature inconsistency
• Verify low side pressure is 25-35 PSI and high side is 175-250 PSI at idle (varies with ambient temperature)
• Confirm no moisture or frost accumulation on AC lines indicating restriction
• Test AC operation in all modes and fan speeds to ensure proper function

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