This procedure covers the removal and replacement of the AC evaporator core, located inside the HVAC housing behind the dashboard on 2015-2020 Ford F-150 trucks with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — Use OEM specification
• AC Line O-ring Kit × 1 — Use OEM specification
• Expansion Valve (if damaged) × 1 — Use OEM specification
• Evaporator Case Foam Seal × 1 — Use OEM specification
• HVAC Cabin Air Filter × 1 — Replace during service
• R-134a Refrigerant × 1 — Approximately 1.75 lbs total system capacity
• PAG 46 Oil × 1 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait minimum 2 minutes for airbag system discharge
3. Recover all AC refrigerant using certified recovery equipment and record amount removed
4. Drain engine coolant into appropriate container (approximately 1-2 gallons will drain)
5. Remove both front seats to provide workspace (four bolts per seat, save for reinstallation)
6. Remove center console completely including all trim panels and cupholders
7. Protect steering column, windshield, and door sills with towels or protective covers
8. Have labeled bags or containers ready for organizing fasteners by location

Procedure

1. 1

   Disconnect AC and heater lines at firewall
   From engine bay, locate AC line connections at firewall on passenger side. Disconnect the liquid line and suction line from evaporator using spring lock coupling tools. Disconnect heater hose quick-disconnects from heater core tubes. Plug all openings immediately with rubber caps to prevent contamination. Remove expansion valve if replacing evaporator core.
2. 2

   Remove lower dashboard panels and trim
   Remove lower dashboard panels on both driver and passenger sides. Remove door sill plates and A-pillar trim on both sides. Remove the cowl side trim panels. Remove knee bolster panel below steering column. Disconnect all visible electrical connectors as you go, labeling each with tape and marker.
3. 3

   Remove steering column and instrument cluster
   Lower steering column by removing four mounting bolts. Disconnect all electrical connectors from column including clockspring connector. Support column and move aside (do not let it hang by wiring). Remove instrument cluster bezel, then remove four screws securing cluster. Disconnect cluster electrical connectors and remove cluster from vehicle.
4. 4

   Disconnect main dashboard electrical and HVAC controls
   Disconnect main dashboard wiring harness connectors located behind center stack. Remove HVAC control head by removing trim panel, then removing mounting screws. Disconnect vacuum lines (if equipped with vacuum-operated mode doors), electrical connectors, and temperature blend door cables. Remove radio and climate control assembly.
5. 5

   Remove dashboard mounting bolts
   Locate and remove all dashboard mounting bolts: typically 4 bolts along top edge near windshield, 2-3 bolts at each A-pillar area, 2 bolts at center support brace, and bolts at lower sides near footwells. There are approximately 10-12 main mounting bolts. Have an assistant help support the dashboard weight.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Remove dashboard assembly
   With assistant supporting passenger side, carefully pull dashboard rearward while checking for any remaining electrical connections or fasteners. Lift and maneuver dashboard assembly out through passenger door opening. This is a two-person operation; dashboard weighs approximately 60-80 lbs. Place on protected surface.
7. 7

   Access and remove HVAC housing
   With dashboard removed, HVAC housing is now visible. Disconnect blower motor electrical connector and remove blower motor assembly. Remove any remaining duct work connected to HVAC case. Remove mounting bracket bolts securing HVAC case to firewall and remove the case screws around the perimeter.
   Torque spec

   Blower Motor Screws8 Nm (6 lb-ft)

   Mounting Bracket Bolts30 Nm (22 lb-ft)
8. 8

   Separate HVAC case halves
   Place HVAC housing on clean work surface. Remove all evaporator case screws around the perimeter seam (typically 12-16 screws). Carefully separate upper and lower case halves. Note orientation of blend door actuators and linkages before complete separation. Remove any duct clips as needed.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)

   Duct Clips3 Nm (2 lb-ft)
9. 9

   Remove old evaporator core
   Lift evaporator core out of lower housing carefully. Note orientation and position of foam seals and insulation. Remove and discard old foam seals from case. Inspect heater core for leaks while case is open. Clean both case halves thoroughly, removing any debris, leaves, or old foam material. Inspect blend doors and actuator operation.
10. 10

    Install new evaporator and seals
    Install new foam seals in lower case half per manufacturer instructions. Add specified amount of fresh PAG 46 oil to new evaporator (typically 2-3 oz; check service manual for exact amount). Install new evaporator into lower case, ensuring proper orientation with tubes facing firewall opening. Install new expansion valve with new O-rings.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
11. 11

    Reassemble HVAC case
    Position upper case half over lower half, ensuring all blend door linkages and actuator arms are properly aligned. Install all evaporator case screws, tightening in star pattern to ensure even seal compression. Verify blend doors move freely after assembly. Install new cabin air filter in housing.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)
12. 12

    Reinstall HVAC housing and blower
    Position HVAC housing back onto firewall studs. Install mounting bracket bolts and torque properly. Ensure evaporator tubes align with firewall openings. Reinstall blower motor assembly and reconnect electrical connector. Reattach any duct work to HVAC case.
    Torque spec

    Mounting Bracket Bolts30 Nm (22 lb-ft)

    Blower Motor Screws8 Nm (6 lb-ft)
13. 13

    Reinstall dashboard assembly
    With assistant, carefully position dashboard assembly back into vehicle through passenger door. Align mounting points and ensure no wiring is pinched. Install all dashboard mounting bolts hand-tight first, then torque in sequence starting from center and working outward. Reconnect all electrical connectors, HVAC controls, and vacuum lines.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
14. 14

    Reconnect AC and heater lines
    From engine bay, install new O-rings on all AC line fittings, lubricating with fresh PAG oil. Connect liquid line and suction line to evaporator tubes at firewall, ensuring proper seating of O-rings. Connect heater hoses to heater core tubes. Torque all AC line fittings to specification.
    Torque spec

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

    Evacuate and recharge AC system
    Connect manifold gauge set and vacuum pump to AC service ports. Pull vacuum on system for minimum 45 minutes, watching for vacuum loss that would indicate leaks. If vacuum holds, recharge system with correct amount of R-134a refrigerant (verify on underhood label, typically 1.75 lbs). Use refrigerant scale for accurate charging. Add UV dye if desired for future leak detection.

Reassembly

1. Reinstall instrument cluster and connect all electrical connectors
2. Reinstall steering column and torque mounting bolts to specification
3. Reinstall all lower dashboard panels, knee bolster, and trim pieces
4. Reinstall A-pillar trim, door sill plates, and cowl side trim on both sides
5. Reinstall center console assembly and all trim panels
6. Reinstall front seats and torque mounting bolts to specification
7. Refill cooling system with Motorcraft Orange Coolant to proper level
8. Reconnect negative battery cable
9. Bleed cooling system by running engine to operating temperature with heater on high

Verification

• Start engine and verify no coolant leaks at heater core connections
• Run AC system and verify cold air output from all vents (should reach 40-45°F at vents)
• Check AC system pressures with gauges: low side should be 25-35 psi, high side 200-250 psi at idle with ambient temp 75-80°F
• Verify all HVAC mode functions operate correctly (defrost, floor, panel, bi-level)
• Test blend door operation by adjusting temperature from cold to hot
• Inspect engine bay and interior for any refrigerant oil residue indicating leaks
• Verify all dashboard functions: gauges, warning lights, radio, climate controls operate normally
• Check that all trim panels and dashboard components are secure with no rattles
• Test all electrical systems affected during dashboard removal: airbag light should not be illuminated
• Road test vehicle and verify AC system maintains temperature and no unusual noises from HVAC system

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