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How do you remove the dash when replacing the heater plenum box in a 1997 Explorer XLT?
Gmeinholz
If what you need to do is replace the heater core, then this is a very hard job. I just did one on a 5.0 V-8 Explorer and it was a nightmare. Since you don't mention heater core replacement I'll assume you want to remove the plenum box for another reason.
To remove the plenum box you will have to remove the steering wheel and unbolt the column from the dash and disconnect the shifter cable, it will then hang down. After that you will find two large bolts at either end of the dash after it curves downward on each end. There are also large bolts running across the top of the dash, probably two on the left above the instrument cluster and two on the right above the glove box. Plus one or two more in the center. All these are under the molding that should just pop out. You will also find a long bracket and bolt under the dash to the left of the glove box and a smaller one on the drivers side which have to be removed. And this is just the big stuff, there are several small lines,cables,nuts, clips and vacumn lines that will have to be removed once the dash is lose. Also to completely remove the plenum box the main wiring harness will have to be disconnected and partially or totally removed as well. If what you're trying to do is replace the heater core then you'll also have to disconnect the air conditioner lines and remove the underhood plenum box as well. This is an extremely hard job especially if you have a V-8, don't try this job at home without experienced help. I did this in a 96 model and there are small changes from year to year but all Explorer's are basically the same. This is one job worth paying for, Good Luck!!
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remove steering column, pull back dash to passenger front seat, you do not have to dis-assemble entire dash panel. You can access plenum (heater box)this way.
