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This repair is not especially difficult, and can be done with just a few simple tools. Remarkably, some repair guides indicate that lowering the steering column and removing the entire dashboard/instrument panel is necessary to perform this repair. No so with my particular 02 Ford F250, which could be the case with yours, too.

Step 1. Lift hood, and disconnect the heater hoses from the heater core in the engine compartment located under the cowl on the passenger's side. To avoid spilling coolant you can partially drain the cooling system, or just pinch off the hoses on the engine side of the connections. The heater core OEM hose connectors are plastic quick-connect couplers which were easy to put on in the factory but hard to take off when doing repairs. I recommend using a Dremel tool with a cut-off disk to cut the plastic connectors. Once cut, the hoses can be pulled off. The quick-connect couplers can the be completely removed from the hoses with a hack saw or angle grinder. When reassembling it is far easier to use regular hose clamps, but new quick-connects could be purchased from a Ford dealer if you want.

Step 2. Enter the cab from the front (if crew cab), passenger's side door, and open the glove compartment. There are 2 stops on the top of the glove compartment. Gently squeeze the glove box sides andlower the glove box so it is hanging down.

Step 3. Remove the heater core access panel which is in back of the glove compartment on the right hand side. It is held in place with several 8mm hex-head self-tapping screws. A 1/8" drive mini-ratchet socket driver comes in handy for this purpose.

Step 4. Remove the vacuum heater door actuator. First disconnect the vacuum connector, then remove 2 8mm hex-head self-tapping screws.

Step 5. Remove the electrical heater door actuator. First disconnect the electrical connector. Then pry up front 2 and left rear corners with a small screwdriver. Rotate actuator then raise up and pull out.

Step 6. Remove the electrical heater door bracket.

Step 7. Remove the heater core by pulling the pipes through the firewall toward you and tilting it out. A picture of the 02Ford F250-350

Follow above steps in reverse order to reinstall. Check and add engine coolant as necessary at the end of the repair.

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13y ago

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