This procedure involves removing the dashboard assembly and HVAC housing to access and replace the AC evaporator core, requiring refrigerant recovery and system recharge.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• Expansion valve O-rings × 1 — Use OEM specification
• AC line O-ring kit × 1 — Use OEM specification
• Evaporator case foam seal × 1 — Use OEM specification
• Cabin air filter × 1 — Use OEM specification
• Dashboard clip assortment × 1 — Use OEM specification
• PAG-46 oil × 1 — 3 oz

Fluids

• R-1234yf refrigerant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify refrigerant type is R-1234yf using refrigerant identifier - do not proceed if contaminated
3. Using certified R-1234yf recovery machine, fully recover refrigerant from AC system and record amount recovered
4. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
5. Set steering wheel to straight-ahead position
6. Remove driver and passenger front seats by unbolting four bolts per seat (save for carpet access)
7. Roll back carpet edges to access floor console mounting bolts
8. Document refrigerant oil amount in recovered refrigerant for replacement calculation

Procedure

1. 1

   Remove instrument cluster and upper dashboard trim
   Remove instrument cluster bezel by pulling outward on left and right edges to release clips. Disconnect hazard switch connector. Remove four T20 screws securing instrument cluster, pull cluster forward, and disconnect two electrical connectors and shift cable (if equipped). Remove upper dashboard trim panels on both driver and passenger sides by releasing clip fasteners working from top to bottom.
2. 2

   Remove center stack and HVAC controls
   Remove center stack trim panel by releasing perimeter clips. Disconnect climate control connectors, USB ports, and any auxiliary switches. Remove four screws securing climate control module and HVAC control head. Carefully pull assembly forward and disconnect all electrical connectors and vacuum lines (if equipped). Label each connector position with tape.
3. 3

   Remove steering column and lower dash panels
   Remove lower steering column cover by removing three T20 screws. Remove upper column cover. Disconnect all electrical connectors at column (ignition switch, column lock, multi-function switches). Remove four bolts securing steering column support bracket and carefully lower column to floor, supporting weight. Remove driver side lower dash panel and knee bolster by removing eight screws and releasing clips.
4. 4

   Disconnect AC line fittings at firewall
   Working in engine bay, locate AC liquid line and suction line connections at firewall near evaporator. Use flare nut wrench to disconnect both fittings from evaporator inlet and outlet. Immediately cap all open AC fittings to prevent moisture and debris entry. Remove and discard all O-rings from fittings.
   Torque spec

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

   Remove main dashboard carrier assembly
   Remove passenger side airbag module by removing four T30 Torx bolts from behind dashboard (access through glove box opening after removing glove box). Disconnect airbag connector with safety clip. Remove eight bolts securing main dashboard carrier to cowl and A-pillar structures (four on driver side, four on passenger side). Disconnect all remaining electrical harnesses at firewall connectors - there are typically 6-8 large multi-pin connectors. With assistance, carefully pull entire dashboard assembly rearward and remove from vehicle.
6. 6

   Remove blower motor assembly
   Locate blower motor housing on passenger side of HVAC unit. Disconnect blower motor electrical connector. Remove three screws securing blower motor to housing using appropriate socket. Carefully pull blower motor assembly straight out from housing to avoid damaging fan wheel.
   Torque spec

   Blower Motor Screws8 Nm (6 lb-ft)
7. 7

   Remove HVAC case upper and lower sections
   Remove duct clips and duct work from HVAC case using trim tools. Remove all cover screws around perimeter of HVAC case housing. Carefully separate upper case from lower case by releasing remaining clips. Note orientation of case halves and airflow door positions before separation.
   Torque spec

   Duct Clips3 Nm (2 lb-ft)

   Cover Screws12 Nm (9 lb-ft)
8. 8

   Remove expansion valve from evaporator
   Locate expansion valve (TXV) attached to evaporator inlet. Remove two bolts securing expansion valve to evaporator core. Carefully separate valve from evaporator tubes. Remove and discard O-rings from expansion valve and evaporator connection points. Cap evaporator openings immediately.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
9. 9

   Remove evaporator core from case
   Remove remaining evaporator case screws securing evaporator mounting brackets. Carefully lift evaporator core assembly straight up and out of lower case half. Note position of thermistor probe and evaporator temperature sensor - disconnect if attached. Inspect case for debris, leaves, or biological growth and clean thoroughly before installing new evaporator.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
10. 10

    Prepare and install new evaporator core
    Add 3 oz of fresh PAG-46 oil to new evaporator core inlet to replace oil lost with old evaporator. Distribute oil by rotating evaporator. Install new foam seals around evaporator perimeter ensuring complete contact with case. Verify thermistor probe mounting location is clear. Carefully lower new evaporator into lower case half, aligning mounting bracket holes.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)
11. 11

    Install expansion valve with new O-rings
    Install new O-rings onto expansion valve connection points - lubricate O-rings with small amount of PAG oil. Position expansion valve onto evaporator inlet tubes, ensuring O-rings seat properly. Install expansion valve mounting bolts and torque to specification. Verify valve is secure and O-rings are not pinched.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
12. 12

    Reassemble HVAC case assembly
    Join upper and lower HVAC case halves, ensuring all airflow doors operate freely and are in correct position. Install all case screws around perimeter and torque to specification. Reinstall ductwork and secure with clips. Verify case is fully sealed with no gaps.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

    Duct Clips3 Nm (2 lb-ft)
13. 13

    Reinstall blower motor
    Insert blower motor assembly into housing, ensuring fan wheel clears housing and rotates freely. Install three mounting screws and torque to specification. Reconnect blower motor electrical connector ensuring positive lock engagement.
    Torque spec

    Blower Motor Screws8 Nm (6 lb-ft)
14. 14

    Reinstall dashboard assembly
    With assistance, position dashboard carrier assembly into vehicle, routing all wiring harnesses through firewall opening. Align dashboard mounting points to cowl and A-pillar structures. Install eight dashboard mounting bolts finger-tight, then torque to specification working from center outward. Reconnect all electrical harness connectors at firewall, verifying positive locks on each connector. Install passenger airbag module and torque four mounting bolts to specification.
    Torque spec

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

    Reconnect AC lines and prepare for charging
    Install new O-rings onto AC liquid line and suction line fittings at firewall - lubricate with PAG oil. Connect both lines to evaporator inlet and outlet fittings, ensuring proper alignment. Torque AC line fittings to specification using flare nut wrench. Remove caps from all fittings. Connect AC service machine to vehicle service ports.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
16. 16

    Vacuum and recharge AC system
    Pull vacuum on AC system for minimum 45 minutes to eliminate moisture and verify system holds vacuum (indicating no leaks). If vacuum holds for 10 minutes without decay, proceed with recharge. Recharge system with R-1234yf refrigerant to original recovered amount plus PAG oil added to evaporator. Use AC machine to verify proper charge weight. Start engine and verify AC operation before final reassembly.

Reassembly

1. Reinstall steering column to support bracket and torque mounting bolts to specification
2. Reconnect all steering column electrical connectors and install column covers
3. Install lower dash panels, knee bolster, and all trim pieces removed during disassembly
4. Reinstall center stack trim, climate control module, and all associated electrical connectors
5. Install instrument cluster, reconnect electrical connectors and shift cable, then install cluster bezel
6. Reinstall front seats and torque mounting bolts to specification
7. Reposition carpet and install floor console
8. Reconnect negative battery terminal
9. Perform any required module relearns or initializations per Ford service procedures

Verification

• Start engine and verify all dashboard warning lights function normally and no new fault codes are present
• Test AC system operation - verify cold air from vents reaches 40-45°F within 5 minutes of operation at idle
• Verify blower motor operates at all speed settings without unusual noise
• Check for refrigerant leaks at evaporator connections using electronic leak detector or UV dye inspection
• Verify all climate control functions operate correctly (mode doors, temperature blend, recirculation)
• Test all dashboard components for proper operation (gauges, switches, displays, airbag light status)
• Inspect AC lines at firewall for signs of refrigerant oil leakage after 15 minutes of operation
• Verify no coolant smell in cabin indicating heater core disturbance during dashboard removal
• Road test vehicle and verify AC performance under load, monitoring both vent temperature and compressor cycling

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