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Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refrigerant Compressor Oil (Mineral Oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to R-134a refrigerant systems as an A/C compressor lubricant. PAG Refrigerant Compressor Oil F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

    ALL VEHICLES 

  1. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the battery.
  4. Remove the battery tray.
    1. Remove the bolts.
    2. Remove the battery tray.
    Fig 1: Removing Battery Tray
    G02766455Courtesy of FORD MOTOR CO.
  5. Position the washer reservoir filler tube aside.
    1. Remove the screws.
    2. Position the filler tube aside.
    Fig 2: Positioning Filler Tube
    G02766456Courtesy of FORD MOTOR CO.
    6. CAUTION: Use a wrench on each side of the fitting to prevent twisting of the refrigerant line.
    Fig 3: Discarding O-Ring Seal
    G02766457Courtesy of FORD MOTOR CO.
  6. Disconnect the evaporator outlet fitting.
    • Discard the O-ring seal.

    7. VEHICLES WITHOUT AUXILIARY A/C 

    CAUTION: Use a wrench on each side of the fitting to prevent twisting of the refrigerant line.
    Fig 4: Disconnecting Fitting
    G02766458Courtesy of FORD MOTOR CO.
  7. Disconnect the compressor manifold and tube suction fitting.
    1. Remove the screw.
    2. Disconnect the fitting.
      • Discard the O-ring seal.

    8. VEHICLES WITH AUXILIARY A/C 

  8. Remove the screw.
    Fig 5: Removing Vehicles With Auxiliary A/C
    G02766459Courtesy of FORD MOTOR CO.
  9. Disconnect the spring lock coupling.
    • Discard the O-ring seals.
    Fig 6: Disconnecting Spring Lock Coupling
    G02766460Courtesy of FORD MOTOR CO.

    10. ALL VEHICLES 

  10. Disconnect the A/C cycling switch electrical connector.
    Fig 7: Disconnecting A/C Cycling Switch Electrical Connector
    G02766461Courtesy of FORD MOTOR CO.
  11. Remove the suction accumulator.
    1. Remove the bolts.
    2. Remove the suction accumulator.
    Fig 8: Removing Suction Accumulator
    G02766462Courtesy of FORD MOTOR CO.
  12. To install, reverse the removal procedure.
    • Install new O-ring seals lubricated in clean mineral oil.
    • Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  13. Evacuate, leak test and charge the refrigerant system. For additional information refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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