A/C - Evaporator Core Replacement
TSB 04-19-609/22/04
EVAPORATOR CORE REPLACEMENT
FORD:
2002-2005 Explorer
MERCURY:
2002-2005 Mountaineer
ISSUE
Should it become necessary to replace the evaporator core on a 2002-2005 Explorer 4dr or Mountaineer vehicle, the evaporator core can now be serviced as a separate unit. It is no longer necessary to replace the entire housing assembly.
ACTION
Refer to the following Service Procedure.
SERVICE PROCEDURE
1. Remove the evaporator housing from the vehicle. Refer to Workshop Manual Section (412-00).
2. Remove the ten (10) evaporator core cover bolts.
3. Remove the evaporator core cover and discard the rope seal.
4. Install the new evaporator core into the housing.
5. Using Motorcraft RTV Silicone Sealant (TA-31) carefully apply a 1/8" bead around the entire evaporator housing groove joint (Figure 1).
6. Reinstall the evaporator core cover. Torque the ten (10) cover bolts using a diagonal pattern to distribute the RTV Sealant evenly.
7. Refer to the Workshop Manual Section 412-00 and reinstall the evaporator case into the vehicle.
PARTS BLOCK
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
19860 42
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