This procedure covers the removal and replacement of the heater core on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine, requiring extensive dashboard disassembly and coolant system draining.

Warnings

Tools required

Parts

• Heater core assembly × 1 — Ford part number DG1Z-18476-A or equivalent
• Heater core foam seals × 1 — Use OEM specification
• O-rings for heater core inlet/outlet tubes × 2 — Use OEM specification
• Dashboard fastener clips (assorted) × 10 — Have extras on hand
• Panel retaining clips × 5 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 13 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Park vehicle on level surface and engage parking brake
3. Place protective covers over front seats and floor to prevent coolant and debris damage
4. Disconnect negative battery terminal and isolate cable
5. Wait minimum 2 minutes for airbag system backup power to discharge
6. Remove engine cover if equipped
7. Relieve cooling system pressure by slowly loosening coolant reservoir cap
8. Place drain pan under engine and drain coolant from radiator petcock and engine block drain
9. Gather all tools and parts before beginning dashboard disassembly

Procedure

1. 1

   Remove lower dashboard panels and knee bolster
   Remove the lower dashboard trim panels on both driver and passenger sides. Remove the driver's knee bolster panel by removing the retaining screws. Disconnect any electrical connectors for lights or switches. Remove the hood release handle and cable from the panel. Store all fasteners and clips organized by location.
   Torque spec

   Dashboard Screws3 Nm (2 lb-ft)
2. 2

   Remove center console and floor components
   Remove the center console by first removing cupholders and any storage compartments. Remove all console mounting screws and carefully lift console up and back. Disconnect electrical connectors for power outlets, USB ports, and any switches. Remove the center floor duct work by removing retaining screws and pulling straight back to release from HVAC housing.
   Torque spec

   Dashboard Screws3 Nm (2 lb-ft)
3. 3

   Disconnect steering column and remove
   Lower the steering column to its lowest position. Remove the steering column shroud covers. Disconnect the shift interlock cable if equipped with column shifter. Remove the intermediate shaft bolt at the steering gear connection and separate. Remove the four steering column mounting bolts and carefully lower the column, supporting its weight. Disconnect all electrical connectors from the column including clockspring connector.
   ⚠Do not rotate the steering wheel after disconnecting the intermediate shaft to prevent clockspring damage.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove instrument cluster and center stack
   Remove the instrument cluster trim bezel by carefully prying with trim tools. Remove the four cluster mounting screws and pull cluster forward. Disconnect all electrical connectors from the back of the cluster and remove. Remove the center stack trim panel including radio and HVAC controls. Remove mounting screws for radio and climate control module. Disconnect all electrical connectors and antenna cable. Remove these components completely.
   Torque spec

   Dashboard Screws3 Nm (2 lb-ft)
5. 5

   Disconnect main dashboard electrical connectors
   Working from both driver and passenger sides, systematically disconnect all electrical connectors from the dashboard harness. This includes connectors for: airbag control module, body control module, HVAC controls, passenger airbag, all lighting, switches, and sensors. Label or photograph each connection. Disconnect the main harness connectors that pass through the firewall if necessary for dashboard removal.
   ℹ️Take detailed photos of connector locations and wire routing before disconnection to ensure proper reassembly.
6. 6

   Remove dashboard carrier mounting bolts
   Locate and remove all dashboard carrier mounting bolts. There are typically 8-10 bolts along the top of the dashboard accessible through the defroster vents and windshield area, bolts at each A-pillar, bolts at the center tunnel, and bolts at the bottom corners. Remove the cowl side trim panels to access A-pillar bolts. Ensure all electrical connections and mechanical fasteners are disconnected before attempting to remove dashboard.
   ⚠Dashboard assembly is heavy and awkward. Have an assistant help support the dashboard during removal to prevent damage or injury.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Remove dashboard assembly
   With an assistant, carefully pull the dashboard assembly rearward and upward to release it from any remaining clips or pins. Carefully maneuver the dashboard out of the vehicle, being careful not to damage the windshield, A-pillars, or door frames. Place dashboard on a padded surface in a safe location. Inspect for any remaining connected wires or fasteners before fully removing.
   ⚠Dashboard weighs approximately 60-80 lbs and requires two people for safe removal.
8. 8

   Drain heater core and disconnect hoses
   Place drain pan under firewall area inside vehicle. From the engine compartment, locate the two heater hoses connected to the heater core tubes at the firewall (passenger side). Use hose clamp pliers to release the clamps and slide them back on the hoses. Carefully twist and pull the hoses off the heater core tubes. Allow any remaining coolant to drain completely. Cap or plug the hoses to prevent coolant spillage.
   ⚠Expect significant coolant spillage inside the vehicle at the heater core connections. Have absorbent materials ready.
   Torque spec

   Heater Hose Clamps3 Nm (2 lb-ft)
9. 9

   Remove HVAC housing components
   With dashboard removed, you now have access to the HVAC housing assembly. Remove any remaining air duct connections. Remove the upper HVAC housing cover by removing the retaining screws around the perimeter. Carefully separate the upper housing from the lower housing, being mindful of blend door linkages and actuator connections. Disconnect any remaining electrical connectors from actuators.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)

   Housing Bolts16 Nm (12 lb-ft)
10. 10

    Remove heater core from housing
    Locate the heater core mounting bracket within the HVAC housing. Remove the heater core mounting bolts or screws securing the core to the housing. Carefully note the position of any foam seals or air baffles. Gently slide the heater core out of the housing, taking care not to damage the fragile cooling fins. Remove and inspect all foam seals and o-rings from the heater core tubes at the firewall pass-through.
    ⚠Heater core fins are extremely delicate and easily damaged. Handle carefully and avoid bending or crushing.
    Torque spec

    Heater Core Mounting8 Nm (6 lb-ft)
11. 11

    Install new heater core
    Install new o-rings on the heater core inlet and outlet tubes, lubricating lightly with coolant. Install new foam seals in the correct positions on the heater core and housing. Carefully slide the new heater core into the HVAC housing, ensuring proper alignment with the firewall pass-through holes. Verify all foam seals are properly positioned to prevent air bypass. Install and torque the heater core mounting fasteners to specification.
    ℹ️Ensure heater core tubes align properly with firewall openings before securing mounting bolts to prevent tube damage.
    Torque spec

    Heater Core Mounting8 Nm (6 lb-ft)
12. 12

    Reassemble HVAC housing
    Reconnect all blend door actuators and verify actuator linkages are properly engaged. Carefully align and install the upper HVAC housing to the lower housing, ensuring no wires or linkages are pinched. Install and torque all housing bolts to specification. Reconnect all air ducts to the housing. Verify all actuators operate freely before proceeding.
    Torque spec

    Housing Bolts16 Nm (12 lb-ft)

    Cover Screws12 Nm (9 lb-ft)
13. 13

    Reconnect heater hoses
    From the engine compartment, install new hose clamps on both heater hoses. Carefully push the heater hoses onto the heater core tubes at the firewall until fully seated. Position the hose clamps approximately 1/2 inch from the tube end and torque to specification. Ensure hoses are routed properly without kinks or sharp bends.
    ℹ️Verify hoses are pushed fully onto the tubes before tightening clamps to prevent coolant leaks.
    Torque spec

    Heater Hose Clamps3 Nm (2 lb-ft)
14. 14

    Reinstall dashboard assembly
    With an assistant, carefully position the dashboard assembly back into the vehicle, aligning all mounting points and ensuring no wires are pinched. Guide the dashboard into position, ensuring it seats properly against the firewall and A-pillars. Install all dashboard carrier mounting bolts and torque to specification in a cross-pattern to ensure even seating. Reconnect all electrical connectors using your reference photos, ensuring all connectors are fully seated and locked.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Reinstall steering column and interior components
    Position the steering column into place and install the four mounting bolts, torquing to specification. Reconnect all steering column electrical connectors including the clockspring. Reconnect the intermediate shaft to the steering gear and torque bolt to specification. Reinstall the instrument cluster, center stack components, console, and all trim panels in reverse order of removal. Torque all dashboard screws to specification. Verify all electrical connections are secure and all switches and controls function properly.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

    Dashboard Screws3 Nm (2 lb-ft)
16. 16

    Refill and bleed cooling system
    Close the radiator petcock and engine block drain. Verify all coolant hose connections are tight. Using a coolant vacuum refill tool if available, refill the cooling system with the specified Motorcraft Orange Coolant to the proper level. If vacuum refill is not available, slowly fill the system through the coolant reservoir, allowing air to escape. Start the engine and allow it to reach operating temperature with the heater on maximum. Monitor coolant level and add as needed. Run engine through several heat cycles, checking for leaks at heater core hose connections and monitoring coolant level.
    ⚠Do not remove coolant reservoir cap when engine is hot. Monitor temperature gauge and shut down immediately if overheating occurs.

Reassembly

1. Reinstall all dashboard components, trim panels, and console in reverse order of removal
2. Reconnect negative battery terminal
3. Verify all electrical systems function properly including HVAC controls, instrument cluster, lights, and switches
4. Check for proper operation of all blend doors and temperature control
5. Verify steering wheel controls and airbag warning light operates normally (should illuminate briefly at startup then extinguish)
6. Reinstall engine cover if equipped

Verification

• Start engine and verify no coolant leaks from heater core hose connections inside engine bay or inside vehicle
• Allow engine to reach operating temperature and verify heater produces hot air at maximum heat setting
• Test all HVAC modes (defrost, floor, panel, mixed) for proper air distribution
• Check coolant level when engine is cold and top off if necessary
• Verify no sweet coolant smell inside vehicle which would indicate a leaking heater core
• Monitor coolant level over the next few days of driving to ensure system is properly filled and no leaks exist
• Check for proper operation of all dashboard controls, switches, and displays
• Verify no warning lights remain illuminated on instrument cluster
• Test all interior electrical functions including lights, power outlets, and switches

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