How hard is it to install a heater core in a 1995 Explorer and how do you do it?

Answer 1

I had to have my heater core replaced. It is a major job. The entire dash had to be removed. I took to local shop. About 6-8 hours labor. Ouch !

This is a brief description of how to access the heater core. Plan at least 8 hours. My first time took 2 weekends. I found that many other descriptions (including the manuals) made me remove lots of items that did not need to be (radio-cd-player). Here are the essentials.

1: Disconnect Battery Terminals

2: Remove the center console

A: Pull the front storage shelves (light pressure) B: Pull the cup holders C: Loosen the screw that holds the wiring harness until the harness is free D: Remove the two bolts from the dash E: Remove the two bolts under the cup holders F: Pull the center console straight back (is held under rear by open ended clip) apply as much pressure as needed.

3: Remove the steering wheel column

A: Remove the emergency brake lever holder B: Remove the hood latch lever holder C: Remove any remaining bolts on the bottom of this cover D: Pull this cover straight back to release from pressure pins E: Remove 4 bolts holding steering column and collar F: Remove bolt from steering column u-joint G: Pull steering column off - lay on front seat

4: Remove the dash-board

A: Remove the dash vent by pulling straight up B: Remove the small screws across the fron that are now exposed C: Remove the kick panels from both sides of the dash D: Remove the passenger air-bag (gain access through the glove-box) E: Disconnect all wiring harnesses on passenger side behind kick pannel F: Get a helper G: Remove the 5 brass bolts (two on left, two in the middle, one on right) H: Remove the dash from the firewall I: Pull passenger side back out of the way to gain access to plenum

5: Remove the Plenum (it may be nessecary to remove the A/C accumulator out of the way for this step - have your A/C coolant removed professionally, then refilled when completed)

A: Remove the 4 bolts holding the plenum to the fire wall (2 inside 2 outside). The hardest bolt to reach is located behing the engine in the middle of the firewall about two feet down and cannot be seen, just felt. B: After removing the plenum, remove the hose from the heater core and pull it through the fire wall.

6: Reassemble