How do you replace heater core on 2004 Ford Taurus?

Answer 1

Replacing a heater core is a challenging repair in any modern car. It would be impossible for anyone to list how to do it. Basically you just have to remove enough of the dash to gain access to the core. The price of a new core is not that expensive but the labor costs to remove and install the new one will shock you. This is a very difficult, time consuming repair. Unless you are comfortable taking your dash apart you would be better off leaving this repair to someone who has done it before. If you do decide to tackle this job take lots of photos and notes along the way so you will know where everything goes. Also put the clips and screws in a sandwich bag so you do not loose them. Go slow and take it easy. Somethings snap apart and other parts and bolted or screwed on. The trick is to know which.

Answer 2

This can be done in about 4-5 hours ( I have done it twice). You actually move the entire dash as one unit rather than picking at it. You must disconnect the steering at the universal joint near the the brake pedal, then remove 2 bolts that hold dash to each doorframe. Next remove 5 -6 screws that hold fascia to front frame right under windshield. Undo 2-3 tight elecrical plugs under right side of dash. Now the entire assembly can swing out on the right side exposing the heater box. There is an excellent video on the whole process, by 'Makuloco' on YouTube.
I found the hardest part was removing the 2 heater tubes on the engine side, these are literally baked on to the core after 10-11 years and there is barely room to get your wrench or hand in there.