the dash has to come out no two ways about it.
Buy some radweld it worked for me
this does not help me take it out nob end
I just went through this nightmare with a 94 escort and it is a pain. The heater core is located in the worst possible location as the instrument panel, dash and trim, environment controllers have to be removed. The speedometer cable has to be disconnected from the engine compartment and from the instrument console. The biggest pain for me was trying to figure out where all the bolts are located that hold down the dash board. The 2 manuals I have only listed 4 bolts down below the console, and I had a hard time figuring out where the rest of them were. There are 2 bolts on each side next to the door fronts and 3 bolts right under the windshield that are accessed by removing the plastic defroster trim in front of the dash. It is held down by one central screw and a bunch of clips. I still have screws left over after putting things back together so try to document where everything comes from... Good luck
The heat exchanger is the most expensive part to replace in your heater. The recommended thing to do would be contact a professional and have it installed. Maintaining proper water chemistry is the key to not having to replace it again. I have seen them be ruined in less that a week due to improper balance. Find your owner's manual that came with the heater and they give explicit advice on taking care of your pool heater.
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