AC Expansion Valve (TXV)

Replace the AC expansion valve (TXV) on a 2011-2014 Ford F-150 with 5.0L V8 Coyote engine, including evacuation and recharge of the AC system.

Warnings

Tools required

Parts

• AC Expansion Valve (TXV) × 1 — Motorcraft YG-341 or equivalent
• AC O-ring kit (various sizes) × 1 — Use OEM specification
• R-134a refrigerant × 1 — Typically 1.75-2.0 lbs total system capacity
• PAG 46 compressor oil × 1 — Motorcraft PAG oil for Ford AC systems

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn engine off and allow to cool completely if recently operated
3. Verify AC system refrigerant type is R-134a using identifier tool (never work on contaminated systems)
4. Gather all replacement parts and verify correct expansion valve for F-150 5.0L application
5. Prepare new O-rings and PAG 46 oil for installation
6. Connect AC recovery machine and verify proper operation before beginning

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to high and low side service ports. Follow machine instructions to fully recover all refrigerant from the system. Record amount recovered for comparison during recharge. Allow system to settle for 5 minutes after recovery completes to ensure all refrigerant is captured.
2. 2

   Access expansion valve location
   The expansion valve is located at the evaporator inlet, typically accessed from under the hood near the firewall on the passenger side. Remove the engine cover by pulling upward on the front clips. Remove any interfering air intake components or wiring harness brackets as needed for access. On 4WD models, you may need to work around front differential vent lines.
3. 3

   Disconnect liquid line from expansion valve
   Locate the liquid line connection at the expansion valve inlet (smaller diameter line from condenser). Using appropriate line disconnect tool, carefully disconnect the liquid line fitting. Immediately cap or plug the open line to prevent moisture entry. Some residual refrigerant or oil may escape; use towels to catch any drips.
   ⚠Even after recovery, small amounts of refrigerant may remain in lines. Wear safety glasses and work in ventilated area.
4. 4

   Disconnect suction line from expansion valve
   Locate the suction line connection at the expansion valve outlet (larger diameter line to compressor). Disconnect the fitting using appropriate tool. Cap or plug this opening immediately. Remove any mounting clips or brackets securing the expansion valve to the evaporator housing.
5. 5

   Remove old expansion valve
   Carefully remove the expansion valve from the evaporator inlet fitting. Note the orientation and position of the valve for proper installation of replacement. On some configurations, the valve may be secured with a retaining bracket or additional fastener. Inspect the evaporator inlet tube for damage or corrosion.
6. 6

   Remove and inspect old O-rings
   Using an O-ring pick, carefully remove all old O-rings from the evaporator fitting and both AC line connections. Inspect sealing surfaces for scratches, corrosion, or damage. Clean sealing surfaces with a lint-free cloth. Do not use abrasive materials on aluminum fittings.
7. 7

   Install new O-rings with PAG oil
   Select correct size O-rings from kit for each connection point. Lightly coat each new O-ring with clean PAG 46 oil before installation. Install O-rings onto evaporator fitting and verify they are seated properly in their grooves without twisting or pinching. Add 2-3 drops of PAG oil into the evaporator inlet tube.
   ℹ️O-rings must be coated with PAG oil for proper sealing and to prevent damage during installation.
8. 8

   Install new expansion valve
   Remove new expansion valve from packaging only when ready to install to minimize moisture exposure. Orient valve correctly (note inlet/outlet markings or directional arrow). Install valve onto evaporator inlet fitting, ensuring O-rings remain in position. If valve has a separate mounting bracket or fastener, install and torque to specification.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
9. 9

   Reconnect liquid line to expansion valve
   Install new O-ring onto liquid line fitting, coating with PAG oil. Add 1-2 drops of PAG oil into the expansion valve inlet. Remove cap from liquid line and quickly connect to expansion valve inlet to minimize moisture exposure time. Hand-tighten fitting first, then torque to specification.
   ℹ️Cross-threading aluminum AC fittings will ruin components. Always start fittings by hand and ensure smooth threading before using tools.
   Torque spec

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

    Reconnect suction line to expansion valve
    Install new O-ring onto suction line fitting, coating with PAG oil. Add 1-2 drops of PAG oil into the expansion valve outlet. Remove cap from suction line and connect to expansion valve outlet. Hand-tighten, then torque to specification. Reinstall any mounting clips or brackets that secure the lines.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Perform vacuum evacuation
    Connect evacuation equipment to both high and low side service ports. Evacuate system to 29.9" Hg (full vacuum) and hold for minimum 30 minutes. System should maintain vacuum without decay. If vacuum decays more than 1" Hg in 30 minutes, there is a leak that must be found and repaired before proceeding.
    ⚠Inadequate evacuation will leave moisture in system, causing corrosion and premature compressor failure. Never skip or shorten vacuum process.
12. 12

    Recharge AC system
    With system still under vacuum, connect refrigerant supply to charging port. Charge system with R-134a refrigerant to specification (typically 1.75-2.0 lbs for F-150 5.0L - verify on underhood label). Add refrigerant with engine running and AC on MAX setting. Monitor pressures on gauges during charging. Final charge amount should match recovered amount (accounting for oil replacement).
13. 13

    Test system operation
    With engine at operating temperature and AC on MAX, verify vent temperature reaches 38-42°F. Check that compressor cycles properly and both high and low side pressures are within specification (typically 25-35 PSI low side, 200-250 PSI high side at 70-80°F ambient). Inspect all connections for signs of refrigerant leaks using leak detector or soap solution.

Reassembly

1. Reinstall any air intake components, engine covers, or wiring brackets removed for access
2. Verify all AC line mounting clips and supports are properly secured
3. Double-check all connection points are tight and show no signs of leakage

Verification

• Start engine and run AC system on MAX cold setting for 10 minutes to verify proper cooling
• Measure vent temperature with thermometer - should achieve 38-42°F in recirculation mode
• Verify compressor clutch engages and disengages properly based on temperature and pressure
• Check that no unusual noises come from expansion valve or evaporator area
• Inspect all connection points for oil residue or frost buildup indicating leaks
• Verify high and low side pressures remain stable and within manufacturer specifications
• Test AC performance at idle and at 2000 RPM to ensure adequate cooling under all conditions

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