This procedure covers the removal and replacement of the AC condenser on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC condenser × 1 — Use OEM specification
• AC line O-rings × 1 — Kit includes multiple sizes
• PAG 46 refrigerant oil × 1 — 50ml minimum
• R-134a refrigerant × 1 — Approximately 1.75 lbs

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
3. Have AC system professionally evacuated and refrigerant recovered, noting the amount removed
4. Allow engine to cool completely if recently driven
5. Raise front of vehicle and support on jack stands if additional clearance is needed for access

Procedure

1. 1

   Remove grille and bumper cover
   Open hood and remove the upper grille by releasing the retaining clips along the top edge. Remove the front bumper cover mounting bolts (typically 6-8 bolts along the top and sides). Disconnect any fog light connectors if equipped. Carefully pull the bumper cover forward to disengage lower clips and remove from vehicle. Set aside in a safe location to avoid scratching.
2. 2

   Disconnect AC lines from condenser
   Locate the AC line connections at the condenser (passenger side near radiator). Use a flare nut wrench to carefully loosen the refrigerant line fittings. Cap all open fittings immediately with plugs or tape to prevent moisture and debris entry. Drain and measure any refrigerant oil that exits the lines into a clean container to determine replacement amount.
   ⚠Even after recovery, residual refrigerant may be present. Work in a well-ventilated area.
3. 3

   Remove radiator support brackets
   Remove the upper radiator support brackets by removing the mounting bolts on each side. On some models, the active grille shutters may need to be disconnected. Remove any plastic covers or shields blocking access to the condenser mounting bolts. Set all fasteners aside in labeled containers.
4. 4

   Disconnect transmission cooler lines if necessary
   If the transmission cooler is integrated with the condenser or blocks access, disconnect the transmission cooler lines using a line disconnect tool. Have a drain pan ready to catch any fluid. Cap the lines to prevent contamination. Note the routing for reinstallation.
   ℹ️Automatic transmission fluid may drain from disconnected cooler lines. Have additional ATF available for top-off after reassembly.
5. 5

   Remove condenser mounting bolts
   Locate the condenser mounting bolts (typically 4 bolts, two at top and two at bottom of condenser). Remove all condenser mounting bolts. Support the condenser while removing the final bolt to prevent it from falling.
   Torque spec

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

   Extract condenser from vehicle
   Carefully tilt the top of the condenser toward the engine bay while lifting upward to clear the radiator support. Maneuver the condenser out of the vehicle, being careful not to damage the radiator or any remaining AC lines. Inspect the condenser mounting area for debris or damage.
7. 7

   Prepare new condenser
   Remove shipping caps from new condenser. Add the appropriate amount of fresh PAG 46 oil to the new condenser (typically 50ml, or match the amount drained from the old system plus 10ml). Install new O-rings on all AC line fittings, lightly coating them with PAG oil before installation. Verify all mounting points match the old condenser.
   ℹ️Using the correct amount of refrigerant oil is critical for compressor longevity. Too much or too little will cause premature failure.
8. 8

   Install new condenser
   Carefully lower the new condenser into position, aligning it with the mounting points on the radiator support. Ensure proper spacing from the radiator to allow adequate airflow. Thread all mounting bolts by hand first to ensure proper alignment before tightening.
9. 9

   Secure condenser mounting bolts
   Torque the condenser mounting bolts to specification in a cross pattern to ensure even clamping force. Verify the condenser is seated properly and does not contact the radiator or other components.
   Torque spec

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

    Reconnect AC refrigerant lines
    Remove protective caps from condenser fittings and AC lines. Verify new O-rings are properly seated. Thread AC line fittings by hand to ensure proper thread engagement. Torque the AC line fittings to specification using a torque wrench and crowfoot adapter.
    Torque spec

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

    Reconnect transmission cooler and supports
    If transmission cooler lines were disconnected, reconnect them ensuring proper seating and secure with clips. Reinstall the radiator support brackets and any shields or covers removed earlier. Torque mounting bracket bolts to specification.
12. 12

    Reinstall bumper and grille
    Reconnect any fog light or sensor connectors. Position the front bumper cover and engage lower clips first, then secure upper mounting bolts. Reinstall the grille assembly, ensuring all clips are fully seated. Verify all panels have proper gaps and alignment.
13. 13

    Vacuum and recharge AC system
    Connect AC service equipment to the high and low side service ports. Evacuate the system to at least 29 inches of vacuum for a minimum of 30 minutes to remove all moisture. Monitor for vacuum decay indicating a leak. If vacuum holds, recharge the system with the amount of R-134a specified on the underhood label (typically 1.75 lbs).
    ⚠Improper evacuation will leave moisture in the system, leading to corrosion and compressor failure. Professional equipment is strongly recommended.
14. 14

    Leak test the system
    With the system charged, use an electronic leak detector to check all connections, particularly the new condenser line fittings. Spray soapy water on connections and look for bubbles. If any leaks are detected, recover refrigerant, repair the leak, and repeat evacuation and recharge process.

Reassembly

1. Reconnect negative battery cable
2. Check transmission fluid level if cooler lines were disconnected and top off as needed
3. Start engine and verify all warning lights extinguish normally
4. Verify all bumper and grille mounting points are secure with no loose panels

Verification

• Start the engine and turn AC to maximum cold with blower on high
• Allow system to run for 5 minutes and verify cold air from vents (typically 38-42°F at center vents)
• Check that compressor cycles on and off normally
• Verify no unusual noises from AC system operation
• Inspect all AC line connections for signs of refrigerant leakage (oil residue)
• Monitor AC performance over the next few days for any degradation
• Verify proper high and low side pressures with gauges (low side: 25-40 PSI, high side: 200-250 PSI at idle, ambient temp dependent)

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