Monday, July 11, 2011

How to remove Evaporator Core on 2005 Ford Explorer

Removal & Installation

If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

  1. Remove the heater core. See -Heater Core- section.
  2. Remove the 5 outer evaporator core cover screws (1).
  3. Remove the 6 inner evaporator core cover screws (2).
  4. Separate the evaporator core cover (3) from the heater core and evaporator core housing. Discard the rope seal.
  5. Remove the evaporator core.

    Click image to see an enlarged view

    Fig. View showing the evaporator core cover (3) and mounting screws (1, 2)

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of the rope seal.
    2. Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant evenly.


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