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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.
  1. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  2. Remove the windshield washer reservoir filler neck bolts.
    Fig 1: Removing Windshield Washer Reservoir Filler Neck Bolts
    G02766463Courtesy of FORD MOTOR CO.
  3. Detach and position the junction box aside.
    Fig 2: Disconnecting Junction Box
    G02766464Courtesy of FORD MOTOR CO.
  4. Disconnect the compressor manifold and tube suction fitting.
    1. Remove the screw.
    2. Disconnect the fitting.
      • Discard the O-ring seal.
    Fig 3: Disconnect The Compressor Manifold And Tube Suction Fitting
    G02766465Courtesy of FORD MOTOR CO.
  5. Disconnect the evaporator outlet fitting.
    • Discard the O-ring seal.
    Fig 4: Disconnecting Evaporator Outlet Fitting
    G02766466Courtesy of FORD MOTOR CO.
  6. Detach the wire harness.
    1. Disconnect the cycling switch electrical connector.
    2. Remove the nut and stud and detach the wire harness.
    Fig 5: Removing Nut And Stud And Detach Wire Harness
    G02766467Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the suction accumulator.
    Fig 6: Removing Bolts And Suction Accumulator
    G02766468Courtesy of FORD MOTOR CO.
  8. 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 .
  9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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