This procedure covers the removal and replacement of the AC condenser on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification for 3.5L EcoBoost
• AC O-ring kit (various sizes) × 1 — Use OEM specification
• PAG 46 refrigerant oil × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As required per capacity label

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure engine is completely cool before beginning work
3. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
4. Verify AC system refrigerant type matches recovery machine (R-1234yf only)
5. Photograph refrigerant line routing and connections for reinstallation reference
6. Place fender covers to protect paint during work

Procedure

1. 1

   Recover AC refrigerant
   Connect certified R-1234yf recovery machine to AC service ports (low-side and high-side). Follow machine instructions to completely recover all refrigerant from the system. Record the amount recovered for recharge reference. Allow system to equalize to atmospheric pressure before proceeding.
   ⚠️Only use certified R-1234yf recovery equipment. Never vent refrigerant to atmosphere.
2. 2

   Remove active grille shutters
   Remove the lower grille assembly by releasing the retaining clips along the bottom edge. Disconnect the electrical connector for the active grille shutter motor. Remove the mounting screws securing the active grille shutter assembly and carefully remove it to access the condenser area.
3. 3

   Remove radiator cover and fan shroud
   Remove the plastic radiator cover by releasing the push-pin fasteners along the top edge. Disconnect the cooling fan electrical connector. Remove the fan shroud mounting bolts and carefully lift the fan shroud assembly upward and out of the engine bay. The electric cooling fan remains attached to the shroud.
4. 4

   Disconnect AC refrigerant lines from condenser
   Locate the refrigerant line connections at the top of the condenser (inlet and outlet). Using a line wrench to prevent rounding, carefully loosen and remove the refrigerant line fittings. Cap or plug all open refrigerant ports immediately to prevent moisture and debris contamination. Discard old O-rings.
   ⚠Ensure AC system is fully discharged before loosening any fittings. Residual pressure can cause injury.
5. 5

   Disconnect transmission cooler lines (if equipped)
   For vehicles with integrated transmission cooler in the condenser, locate the transmission cooler line connections at the bottom of the condenser. Use a line wrench to disconnect both transmission cooler lines. Have a drain pan ready as residual ATF will drain. Cap or plug all open transmission cooler ports to prevent contamination.
   ℹ️Some F-150 configurations route transmission cooler through the condenser. Verify your configuration before proceeding.
6. 6

   Remove condenser mounting hardware
   Locate the condenser mounting bolts along the top edge of the condenser assembly (typically 4 bolts). Remove all condenser mounting bolts. Support the condenser with one hand while removing the final bolts to prevent it from falling.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
7. 7

   Remove condenser from vehicle
   Carefully tilt the top of the condenser toward the engine bay while lifting upward. Maneuver the condenser out from between the radiator and grille opening, being careful not to damage radiator fins or cooling system components. Inspect the rubber mounting isolators and replace if damaged or deteriorated.
8. 8

   Prepare new condenser for installation
   Inspect the new condenser for shipping plugs and remove them. Add the specified amount of fresh PAG 46 refrigerant oil to the new condenser (typically 1-2 oz unless condenser is pre-charged - verify service information). Install new O-rings on all refrigerant line connections and lightly coat them with fresh refrigerant oil. Install new O-rings on transmission cooler connections if equipped.
   ℹ️Use only PAG 46 oil compatible with R-1234yf refrigerant. Do not use PAG oil from R-134a systems.
9. 9

   Install new condenser
   Carefully maneuver the new condenser into position between the radiator and grille opening, reversing the removal process. Ensure the condenser seats properly on the lower mounting isolators. Align the mounting holes at the top of the condenser with the mounting brackets on the radiator support.
10. 10

    Secure condenser mounting bolts
    Install all condenser mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, torque the condenser mounting bolts in a cross-pattern to ensure even seating. Verify the condenser is properly seated and does not contact the radiator.
    Torque spec

    Condenser Mounting Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect transmission cooler lines
    If equipped with integrated transmission cooler, reconnect both transmission cooler lines to the condenser. Ensure connections are clean and free of debris. Tighten fittings to the specified torque for line fittings. Verify connections are secure and properly seated.
    Torque spec

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

    Reconnect AC refrigerant lines
    Remove caps or plugs from refrigerant ports. Verify new O-rings are properly seated in the fittings with a light coat of refrigerant oil. Connect the AC refrigerant lines to the condenser inlet and outlet ports. Hand-tighten first, then use a line wrench to torque AC line fittings to specification. Do not over-tighten as this can damage the O-rings.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
13. 13

    Reinstall fan shroud and accessories
    Position the fan shroud and electric cooling fan assembly back into place, ensuring it seats properly on the lower mounting tabs. Install and torque the fan shroud mounting bolts. Reconnect the cooling fan electrical connector. Reinstall the radiator cover using the push-pin fasteners.
14. 14

    Reinstall active grille shutters
    Position the active grille shutter assembly and secure with mounting screws. Reconnect the grille shutter motor electrical connector. Install the lower grille assembly and secure all retaining clips. Verify all grille components are properly secured.
15. 15

    Evacuate and recharge AC system
    Reconnect the battery negative cable. Connect AC service equipment to high and low-side service ports. Evacuate the AC system for minimum 30 minutes using a vacuum pump to remove all moisture and air. System should hold vacuum for 10 minutes without loss. Recharge system with R-1234yf refrigerant to the capacity specified on the underhood label (typically 1.5-1.9 lbs). Add UV dye if desired for future leak detection.
    ⚠System must hold vacuum for at least 10 minutes. If vacuum is lost, there is a leak that must be repaired before charging.

Reassembly

1. Verify all refrigerant and transmission cooler line connections are properly torqued and secure
2. Ensure all electrical connectors for cooling fans and grille shutters are fully seated
3. Check that no tools or parts were left in the engine bay
4. Verify active grille shutters operate correctly after battery reconnection

Verification

• Start engine and turn AC to maximum cooling. System should begin cooling within 2-3 minutes
• Check compressor clutch engages and AC system cycles normally
• Inspect all refrigerant line connections for leaks using electronic leak detector or soap solution
• Verify condenser cooling fan activates when AC is on and head pressure increases
• Check transmission cooler lines (if equipped) for leaks with engine running
• Monitor AC system pressures: typical range is 25-45 PSI low-side and 200-275 PSI high-side at idle with 80°F ambient
• Verify AC vent temperature reaches 38-42°F with system fully operational
• Test active grille shutters operate correctly through normal drive cycle

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