1991 1999 ford explorer chilton User Manual

From inside the engine compartment, disconnect the heater hoses from the core fittings ...
Disconnect the heater hoses from the heater core tubes and plug hoses.
2. 
In the passenger compartment, remove the four screws attaching the heater core access cover to the
plenum assembly and remove the access cover.
3. 
... then, in the passenger compartment, remove the under dash cover retaining screws ... HOW TO USE THIS BOOK
674 REMOVAL & INSTALLATION 

... and allow the cover to drop down. If necessary, you can remove the cover if it is in your way
Remove the heater core access panel attaching screws ...
... then remove the cover by pulling downward and straight back to disengage the drain tube (arrow)
Pull the heater core rearward and down, removing it from the plenum assembly.
4.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 675 

Pull the heater core rearward and down to remove it from the plenum assembly
To install:
Position the heater core and seal in the plenum assembly.
1. 
Install the heater core access cover to the plenum assembly and secure with four screws.
2. 
Install the heater hoses to the heater core tubes at the dash panel in the engine compartment. Do not
over-tighten hose clamps.
3. 
Check the coolant level and add coolant as required. Connect the negative battery cable.
4. 
Start the engine and check the system...

When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and
are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless
it is contaminated or several years old.
Disconnect the heater hoses from the heater core tubes and plug hoses.
2. 
Remove the five nuts that secure the blower motor...

Example of the control head and the air flow paths in the plenum assembly (with A/C)
Click to enlarge
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
678 REMOVAL & INSTALLATION 

Exploded view of a cable equipped control head
Click to enlarge
Front and rear view of a cableless control head
Disconnect the negative battery cable.
1.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 679 

On 1331-34 models, open the ash tray and remove the 2 screws that hold the ash tray drawer slide to
the instrument panel. Remove the ash tray and drawer slide bracket from the instrument panel.
2. 
On 1335-33 models, remove the radio.
3. 
Gently pull the finish panel away from the instrument panel and the cluster. The finish panel pops
straight back for approximately 1 inch (25.4mm), then up to remove. Be careful not to trap the finish
panel around the steering column.
4. 
If equipped with the electronic...

Control Cables
ADJUSTMENT
Function Selector and Temperature Selector Control Cable
To check the temperature cable adjustment, move the temperature control lever all the way to the left, then
move it all the way to the right. At the extreme ends of lever travel, the door should be heard to firmly seat,
indicated by a loud thumping sound, allowing either maximum or no air flow through the heater core. To
check the function cable adjustment, see that the function lever will reach the detents at the far...

Control cable connections at the head and the air plenum
Click to enlarge
Control cable routing diagram Click to enlarge
Temperature and Function Cables Disconnect the negative battery cable.
1. 
Remove the control assembly from the instrument panel.
2.  HOW TO USE THIS BOOK
682 REMOVAL & INSTALLATION 

Disengage the glove compartment door by squeezing the sides together and allowing the door to hang
free.
3. 
Working through the glove compartment and/or control opening, remove the temperature and
function cable jackets from their clips on top of the plenum by compressing the clip tans and pulling
the cables upward.
4. 
Reach through the glove compartment opening and disconnect the function and temperature cables
from their separate cams. The cable ends are secured to the cams under a retention finger....