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Head Studs...How To Pull A/C?

11888 Views 11 Replies 5 Participants Last post by  twoicebergs
I need help. I am stuck trying to get the ac evap out. I have spent too much time on it already.

I got the six nuts off from behind the glove box. I took out the actuator motor and tray to get the upper left nut off. I also unplugged the the air hoses (black, grey, and white).

She should be loose at this point, right?

Does anyone have a write up on the removal? Pictures, or a video would be great!
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Ok, sometimes it just doesn't play nice. Regardless, you will still need to remove the vacuum pump and the canister. I would recommend to evacuate the AC, undue the pipes, and pull it all straight forward as one unit. It is really fast this way!

If you want to leave it hooked up, you need to take off the valve cover, the heat-shield - a few of the push on clips are a PITA to reach or find, and the cover for the coil (rad). Unscrew the condenser from the side as well. To get the coil/exchanger out, you might be in for a fight, but sometimes it comes out nicely. Look at the pictures and see the angle I have on it to get it out. You don't want the HVAC box too far forward, or it will bind on the HPO oil rail. A little tip is to cut 1/2 of the alignment tab off so it doesn't damage the fins.

One of the upper bolts on the top is behind the glove box. go straight up from the lower one that is right by/behind the side kick panel.

Once you get it free, you can pull it up and then pull the whole HVAC box out. You will find it will go in easier.... Same for the AC coil as it is unstuck.



Upper left needs a long extension. The one you see to the right, no need to remove it. The extreme right one is same height hidden behind glove box.




Cover off and ready to remove or install. Note angle. It helps to undue the clips on the one pipe.


Pull it up and forward to make room to pull the box.





Reverse order installation.

One extra shot of the coil/exchanger.

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Thanks for the response and pics. Sounds like I am almost there!
actually only 5 of the nuts need removed. the top center one doesn't do anything :D
There's no need to split the cases either. Lowering or removing the fender liner also REALLY helps.
I take the fenderwell out too. makes it much easier to get the case out too. once you've done a few they come right out
Yeah I pull the fender liner down too. I think it was 7 bolts and a black plug thing (forgot what those are called). Takes an extra 5-10 min to get it pulled down and gives you a lot more room.

Good luck, I used pics from the two sticky build threads and youtube to do mine. I've also got a lot of pics posted. If you need anything just yell and we will be happy to help.
Thanks guys. I got it out. I already had the wheel well liner removed (I might dynamat the backside), unplugged the the air hoses (black, grey, and white), and the six nuts (only five needed) from in the cab. I then removed the vacuum pump, air reservoir?, and the other thing attached to the sidewall. Last, I emptied the system, disconnected the condenser pump to dryer and the lower system hose to the evap (had my nifty Lisle tool for the later), and she finally came out.

No way you can lift UP and out (I have an early 2006 6.0). It just came strait out with some muscle. I still had the valve cover on and transmission dip stick in.
The up and forward was only for the coil/exchanger if you left the AC charged. If I had to do it again for head-studs, I would just raise the cab. It would be much faster and easier on the body (mine).

If I had to work on the HVAC, I would just evacuate it and pull all of it straight out. No need to pull the fender well, unless you wanted to stand in it. For the recharge use a hydrocarbon earth friendly filler. Then you can remove it at will for all further repairs.
twoicebergs, thank you for your help.
The up and forward was only for the coil/exchanger if you left the AC charged. If I had to do it again for head-studs, I would just raise the cab. It would be much faster and easier on the body (mine).

If I had to work on the HVAC, I would just evacuate it and pull all of it straight out. No need to pull the fender well, unless you wanted to stand in it. For the recharge use a hydrocarbon earth friendly filler. Then you can remove it at will for all further repairs.
Twoicebergs, I'm about to put everything back together (better late than never). Do you have a make or model suggestion on a hydrocarbon earth friendly filler? Sounds interesting.
Duracool® 6 oz Mobile A/C 12a Refrigerant
Enviro-Safe R134a R12 Replacement AC Refrigerant + Dye 1 Can 12a
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