This procedure covers the removal and replacement of the AC condenser on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including refrigerant recovery, condenser removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-rings × 1 — Various sizes, purchase kit
• PAG 46 oil × 1 — Ford VC-23 or equivalent
• R-134a refrigerant × 1 — Approximately 1.75 lbs

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool completely if recently driven
3. Disconnect negative battery cable
4. Connect AC recovery machine and recover all refrigerant from the system according to machine instructions
5. Record the amount of refrigerant recovered for recharge reference
6. Raise and support front of vehicle on jack stands if needed for additional access

Procedure

1. 1

   Remove grille and upper radiator cover
   Open the hood and remove the upper grille shutters assembly. Remove the retaining screws and clips securing the grille assembly. On most F-150 models, remove the center grille section by releasing the upper clips and lower tabs. Remove the upper radiator sight shield by removing the retaining screws across the top of the radiator support.
2. 2

   Remove active grille shutter motor and brackets
   Disconnect the electrical connector from the active grille shutter motor. Remove the mounting bolts securing the active grille shutter assembly to the upper radiator support. Carefully remove the shutter assembly and set aside. This provides access to the condenser mounting area.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
3. 3

   Disconnect AC lines from condenser
   Locate the AC line connections at the top of the condenser on the passenger side. Use a line wrench to loosen the AC line fittings. Cap or plug all open AC fittings immediately to prevent moisture and contamination from entering the system. Remove and discard all old O-rings from the fittings.
   ⚠Use line wrenches (flare nut wrenches) to prevent rounding off the aluminum fittings. Do not use standard open-end wrenches.
   Torque spec

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

   Disconnect transmission cooler lines if equipped
   If your F-150 has an auxiliary transmission cooler integrated into the AC condenser, disconnect the transmission cooler lines using a line wrench. Have a drain pan ready as some fluid will drain. Cap the lines to prevent contamination. Note the routing for reinstallation.
   ℹ️Not all F-150 models have integrated transmission coolers in the condenser. Skip this step if your condenser does not have cooler lines.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove condenser mounting bolts
   Locate the condenser mounting bolts at the top of the condenser assembly, typically two bolts securing the condenser to the radiator support. Remove these mounting bolts. The condenser may also have lower mounting tabs that slide into brackets on the lower radiator support.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
6. 6

   Remove condenser from vehicle
   Carefully tilt the top of the condenser toward the engine and lift upward to disengage the lower mounting tabs from the radiator support. Maneuver the condenser out from between the radiator and grille opening. Be careful not to damage the radiator fins during removal. Drain any remaining oil from the old condenser into a clean container and measure the amount.
   ⚠Support the condenser carefully during removal to avoid damaging the radiator or cooler lines. Work slowly to prevent fin damage.
7. 7

   Prepare new condenser
   Remove the protective caps from the new condenser. Add the same amount of fresh PAG 46 oil to the new condenser as was removed from the old unit, plus 1 additional ounce to account for residual oil in the old condenser. Install new O-rings on all AC line fittings, lightly coating them with clean PAG oil before installation.
   ℹ️If the old condenser was dry or you cannot measure oil removed, add 3 ounces of PAG 46 oil to the new condenser as a baseline charge.
8. 8

   Install new condenser
   Position the new condenser into the vehicle, inserting the lower mounting tabs into the radiator support brackets first. Tilt the condenser into position, ensuring it sits properly against the radiator without damaging fins. Align the upper mounting holes with the radiator support.
9. 9

   Install condenser mounting bolts
   Thread in the upper condenser mounting bolts by hand first to ensure proper alignment. Torque the mounting bolts to specification using a torque wrench. Verify the condenser is seated properly and not binding against the radiator.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
10. 10

    Reconnect AC lines to condenser
    Remove the protective caps from the condenser ports and AC lines. Verify the new O-rings are properly seated in the fittings. Connect the AC lines to the condenser ports, threading the fittings by hand until finger-tight to ensure proper thread engagement. Use a line wrench to torque the fittings to specification.
    Torque spec

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

    Reconnect transmission cooler lines if applicable
    If transmission cooler lines were disconnected, reconnect them to the condenser ports using new O-rings if provided. Route the lines in their original positions and torque the fittings to specification. Wipe away any spilled transmission fluid.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
12. 12

    Reinstall active grille shutter and grille assembly
    Reinstall the active grille shutter assembly and mounting bolts, torquing to specification. Reconnect the electrical connector to the shutter motor. Reinstall the upper radiator sight shield and cover screws. Reinstall the grille assembly by engaging the lower tabs first, then securing the upper clips and fasteners.
    Torque spec

    Condenser Mounting Bolts12 Nm (9 lb-ft)
13. 13

    Evacuate and recharge AC system
    Reconnect the battery. Connect the AC recovery/recharge machine to the service ports. Evacuate the system for a minimum of 30 minutes to remove all air and moisture. Monitor for vacuum loss to verify system integrity. If vacuum holds, recharge the system with the manufacturer-specified amount of R-134a refrigerant (approximately 1.75 lbs, verify on underhood label). Add UV dye if desired for future leak detection.
    ⚠System must hold vacuum for at least 10 minutes after evacuation. Any vacuum loss indicates a leak that must be repaired before charging.

Reassembly

1. Verify all grille components and fasteners are properly secured
2. Check transmission fluid level if cooler lines were disconnected and top off as needed
3. Inspect the area around the condenser for any tools or parts left behind

Verification

• Start the engine and turn AC to maximum cold with blower on high
• Verify cold air comes from vents within 2-3 minutes of operation
• Check all AC line connections for leaks using a leak detector or soap solution
• Verify active grille shutters operate properly (if equipped) by observing movement during warm-up
• Monitor AC performance over the next few days and check for any refrigerant leaks
• Verify transmission cooler lines have no leaks if they were disconnected

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