Removal & Installation

Remove the instrument panel. For additional information, refer to INSTRUMENT PANEL .
Drain the coolant from the radiator so the coolant level is below the heater core.
Disconnect the heater water hoses.

Fig 1: Identifying Heater Water Hoses
Courtesy of FORD MOTOR CO.
Inside the vehicle, remove the nut.

Fig 2: Identifying Nut
Courtesy of FORD MOTOR CO.

NOTE: Mark the locations of the vacuum hoses.

Fig 3: Identifying Vacuum Hoses

Courtesy of FORD MOTOR CO.

Disconnect the vacuum hoses.
Disconnect the vacuum hose.

Fig 4: Identifying Vacuum Hose
Courtesy of FORD MOTOR CO.
Remove the pin-type retainers and remove the vacuum harness.

Fig 5: Identifying Vacuum Harness
Courtesy of FORD MOTOR CO.
Disconnect the connector.

Fig 6: Identifying Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nuts.

Fig 7: Identifying Retaining Nuts
Courtesy of FORD MOTOR CO.
Disconnect the connectors.

Fig 8: Identifying Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the in-car temperature sensor hose (if equipped).

Fig 9: Identifying In-Car Temperature Sensor Hose
Courtesy of FORD MOTOR CO.

CAUTION: Do not excessively cut the rear footwell duct. Make sure to only cut the rear footwell duct to the point that allows the heater floor duct to be removed with the plenum chamber as an assembly.

Fig 10: Identifying Rear Footwell Duct

Courtesy of FORD MOTOR CO.

Position back the carpet from the plenum chamber. Cut each side of the rear footwell duct and bend back the duct.
Remove the plenum chamber.

Fig 11: Identifying Plenum Chamber
Courtesy of FORD MOTOR CO.

NOTE: Make sure to sufficiently seal the rear footwell duct to the heater outlet floor duct.

For installation, reverse the removal procedure.
- Clean and lubricate the coolant hose with MERPOL(R) or plain water only if needed.
- Close the rear footwell duct around the heater outlet floor duct, install a tie strap, and position back the carpet.
  
  Fig 12: Identifying Tie Strap
  Courtesy of FORD MOTOR CO.