Expansion Block/Orifice Tube: Service and Repair

NOTE: The fixed orifice tube is constructed with a plastic body, two screens and a small brass tube down the center of the orifice body. Two O-rings are around the orifice tube body to seal against leakage around the body. Do not attempt to remove the fixed orifice tube with pliers or to twist or rotate the orifice tube in the evaporator core tube. To do so will break the fixed orifice tube body in the evaporator core tube. Use only the recommended tool following the recommended service procedures.

REMOVAL
1. Discharge the refrigerant from the A/C system into an approved recovery unit. Observe all safety precautions.
2. Disconnect the liquid line from the evaporator core. Cap the liquid line to prevent the entrance of dirt and excessive moisture.
3. Pour a small amount of clean refrigerant oil into the evaporator core inlet tube to lubricate the tube and orifice 0-rings during removal of the fixed orifice tube from the evaporator core tube.

Fixed Orifice Tube Removal:

4. Engage the orifice remover tool Motorcraft Tool YT-1008 or equivalent with the two tangs on the fixed orifice tube. Do not twist or rotate the fixed orifice tube in the evaporator core tube as it may break off in the evaporator core tube.
5. Hold the T-handle of the remover Tool YT-1008 or equivalent, to keep it from turning and run the nut on the tool down against the evaporator core tube until the orifice is pulled from the tube.
6. If the fixed orifice tube breaks in the evaporator core tube, it must be removed from the tube with an extractor, Motorcraft Tool YT-1009 or equivalent.
7. To remove a broken orifice tube, insert the screw end of the extractor, Tool YT-1009 or equivalent, into the evaporator core tube and thread the screw end of the tool into the brass tube in the center of the fixed orifice tube. Then, pull the fixed orifice tube from the evaporator core tube.
8. If only the brass center tube is removed during Step 7, insert the screw end of Tool YT-1009 or equivalent into the evaporator core tube and screw the end of the tool into the fixed orifice tube body. Then, pull the fixed orifice tube body from the evaporator core tube.

INSTALLATION
1. Lubricate the O-rings on the fixed orifice tube body liberally with clean refrigerant oil.
2. Place the fixed orifice tube in the remover, Tool YT-1008 or equivalent, and insert the fixed orifice tube into the evaporator core tube until the orifice is seated at the stop.
3. Remove the remover tool from the fixed orifice tube.
4. Using a new O-ring lubricated with clean refrigerant oil (D1VY-19577-B or equivalent, connect the liquid line to the evaporator core tube. Tighten the fitting using a backup wrench.
5. Leak test, evacuate and charge the system following the recommended service procedures. Observe all safety precautions.
6. Check the system for proper operation.