A/C - Water Leaks From the Floor Ducts
Article No.94-2-12
01/26/94
AIR CONDITIONING - WATER DRIPS FROM THE FLOOR DUCTS WHEN A/C IS OPERATING - VEHICLES BUILT FROM JOB-1 1989 THROUGH 10/15/93
FORD:
1989-94 THUNDERBIRD
LINCOLN-MERCURY:
1989-94 COUGAR
ISSUE:
Condensation may drip from the floor duct when the A/C is operating. This occurs because the location of the evaporator core inside the housing allows high velocity air to carry water droplets from the core face beyond the sump area in the housing.
ACTION:
Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details.
NOTE:
USE PROCEDURE # 1 FOR 1994 MODELS ONLY AND USE PROCEDURE # 2 FOR 1989-93 MODELS.
CAUTION:
OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE.
PROCEDURE # 1 - 1994 MODELS BUILT BEFORE 10/15/93 ONLY
NOTE:
THIS VEHICLE USES THE NON-CHLOROFLUOROCARBON (NON-CFC) BASED REFRIGERANT R-134a. R-134a A/C SYSTEMS REQUIRE THE USE OF SPECIAL SERVICING EQUIPMENT DESIGNED SPECIALLY FOR SERVICING R-134a A/C SYSTEMS
CAUTION:
DO NOT USE R-12 SPECIAL TOOLS AND EQUIPMENT WHEN SERVICING AN R-134a SYSTEM. DOING SO MAY CAUSE DAMAGE TO THE A/C SYSTEM. REFER TO THE ROTUNDA CATALOG FOR MORE INFORMATION ON R-134a SPECIAL SERVICING EQUIPMENT.
1. Record radio stations.
2. Disconnect battery ground cable. Disconnect positive battery and wait one (1) minute for the air bag diagnostic monitor to deplete the air bag back-up power supply. Refer to Service Manual Section 01-20B.
3. Loosen main wiring connector bolt in engine compartment at LH side of dash panel and separate connectors, Figure 1.
4. Remove the radio antenna through the right front wheel well. Disengage the antenna wire grommet from the sheet metal and push the antenna lead-in cable through the sheet metal into vehicle interior.
5. Remove the screws retaining the RH and LH scuff plates (do not remove the scuff plates from the vehicle). Lift scuff plates and remove door opening weatherstrips from body flanges.
6. Remove both RH and LH windshield side garnish moldings.
7. Remove both RH and LH cowl side trim panels.
8. Remove instrument panel steering column cover:
a. remove the three (3) screws along the bottom
b. pull on cover to unsnap the three (3) clips across the top.
9. Remove one (1) screw and A/C evaporator register duct from under the steering column tube.
10. Disconnect the electrical connectors at the base of the steering column.
11. Remove the pinch bolt attaching the steering column tube to steering column lower yoke and slightly spread the joint with a screwdriver.
12. Disconnect the multi-function switch connector located under the column assembly.
13. Disconnect the ignition switch connector.
14. While supporting the steering column tube, remove the four (4) steering column tube retaining nuts.
15. Lower steering column and remove shift interlock cable retaining screws and shift actuator cable fitting. Disconnect the electrical connector from shift interlock solenoid.
16. Remove steering column from the vehicle.
17. Disconnect stop lamp switch, Figure 2.
18. Pull back the floor carpet as required on the RH and LH sides of the vehicle and disconnect the window regulator safety switch connector and the Powertrain Control Module connector.
19. Remove glove compartment:
a. Open glove compartment to the stop.
b. Unsnap the hydraulic lift from the right side of the glove compartment.
c. Remove the three (3) screws at the bottom retaining the glove compartment door hinge and glove compartment to the instrument panel.
d. Remove glove compartment from the instrument panel.
20. Reach through the glove compartment opening and disconnect the electrical and vacuum connectors from the heater-A/C evaporator housing.
21. Disconnect the connectors behind the RH kick panel, Figure 3.
22. Disconnect the two (2) speed control amplifier connectors.
23. Remove floor console panel. Refer to the 1994 Thunderbird/Cougar Service Manual, Section 01-12-4 and 01-12-5.
NOTE:
PROTECT THE INSTRUMENT PANEL SURFACE DURING THE FOLLOWING PROCEDURE.
24. Remove two (2) nuts and one (1) bolt from the instrument panel-to-console mount, Figure 4.
25. Remove two (2) nuts retaining the LH side of instrument panel to cowl side, Figure 4.
26. Remove the nut attaching the RH side of instrument panel to cowl side, Figure 4.
NOTE:
THE FOLLOWING THREE STEPS REQUIRE TWO TECHNICIANS.
27. Remove 6 bolts from the top of the instrument panel, Figure 4.
28. Carefully pull the instrument panel away from windshield glass, checking for and disconnecting any remaining wiring connectors.
29. Remove the instrument panel from the vehicle.
30. Recover the R-134a refrigerant from the A/C system at the service access gauge port valve, following the proper recovery procedure.
CAUTION:
OBSERVE ALL SAFETY PRECAUTIONS.
31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
32. Place a drain pan or suitable container under heater hose connections at the cowl panel.
33. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core.
34. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment.
35. Remove the suction accumulator drier from its bracket then remove the bracket.
36. Remove the three (3) retaining nuts attaching the evaporator housing to the cowl panel (under the hood).
37. Remove one (1) screw at the base of the evaporator housing and one (1) screw at the evaporator housing-to-cowl panel bracket.
38. Remove the evaporator housing from the vehicle.
39. Transfer the parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. See illustrations.
40. Install the evaporator case and instrument panel in the vehicle by reversing the removal procedure.
41. Refill coolant and check for leaks.
42. Recharge the A/C system and check the operation of the system.
43. Reset radio stations recorded in step # 1.
NOTE:
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.
PROCEDURE # 2 - 1989-93 MODELS
NOTE:
AUTOMATIC TEMPERATURE CONTROL - EQUIPPED UNITS BUILT BEFORE 7/1/92 WILL REQUIRE A NEW ASPIRATOR ASSEMBLY (F4SZ-19E628-A) ALONG WITH THE NEW EVAPORATOR CASE ASSEMBLY.
CAUTION:
OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE.
1. Record radio stations.
2. Disconnect battery ground cable.
3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top).
4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel.
5. Remove steering column upper and lower shrouds.
6. Disconnect wiring from steering column.
7. Remove shift interlock switch, if equipped.
8. Disconnect steering column lower universal joint.
9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle.
10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket.
11. Remove RH and LH side cowl trim panels.
12. Disconnect electrical connections at RH cowl side.
13. Remove two (2) instrument panel-to-floor tunnel nuts.
14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor.
15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening.
16. Remove two (2) screws at RH side retaining instrument panel to cowl side.
17. Remove two (2) screws at LH side retaining instrument panel to cowl side.
18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side.
19. Remove RH and LH roof rail trim panels.
20. Remove four (4) screws retaining instrument panel to cowl top.
21. Gently pull instrument panel away from RH side of cowl panel.
22. Place a drain pan or suitable container under heater hose connections at the cowl panel.
23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure.
CAUTION:
OBSERVE ALL SAFETY PRECAUTIONS.
24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core.
26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment.
27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel.
28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel.
29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel.
30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench.
31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle.
NOTE:
IF THE UNIT IS EQUIPPED WITH ATC AND WAS BUILT PRIOR TO 7/1/92, YOU WILL HAVE TO USE A NEW ASPIRATOR (F4SZ-19E628-A) THAT IS DESIGNED FOR THE NEW SERVICE CASE AND ELIMINATE THE OLD ASPIRATOR. CHANGE OVER TO THE NEW ASPIRATOR AS FOLLOWS:
^ TRANSFER THE GASKET FROM THE EXISTING ASPIRATOR ASSEMBLY PLATE TO THE BACK OF THE BLOWER SPEED CONTROLLER SO YOU WILL SEAL THE MATING SURFACE OF THE CONTROLLER TO THE CASE. INSTALL THE BLOWER SPEED CONTROLLER TO THE CASE WITHOUT THE OLD ASPIRATOR, MAKING CERTAIN THAT THE GASKET SEALS PROPERLY.
^ DISCARD THE EXISTING ASPIRATOR ASSEMBLY AND INSTALL THE NEW ASPIRATOR (F4SZ-19E628-A) IN THE UPPER CASE HALF, IN THE EXISTING HOLE NEXT TO THE MUFFLER ASSEMBLY, USING A SCREW (# 10-12X .75 HEX WASHER HEAD SELF-TAPPING); OBTAIN LOCALLY.
^ USING THE OLD ASPIRATOR CONNECTING TUBE, CUT IT TO SIZE (SHORTEN) AND INSTALL IT BETWEEN THE NEW ASPIRATOR AND THE MUFFLER.
32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area.
Cut Off The End Of The Drain Tube, Do Not Drill.:
CAUTION:
DO NOT DRILL OUT THE HOLE BECAUSE THE HEATER CORE COULD BE DAMAGED, FIGURE 5.
Connect A Hose To The Drain Tube.:
33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6.
34. Install the evaporator case in the vehicle by reversing the removal procedure.
a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 2 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube.
b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A).
35. Recharge the A/C system and check the operation of the system.
36. Reset radio stations recorded in step # 1.
NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.
NOTE:
IF EVAPORATOR CORE AND HOUSING ASSEMBLY IS REPLACED PER THIS TSB ARTICLE, IT WILL NOT BE NECESSARY TO PERFORM TSB 94-2-9.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-12-8
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Models; Basic Warranty Coverage For All Other Models
OPERATION DESCRIPTION TIME
940212A Remove And Replace 4.5 Hrs.
Evaporator Case
DEALER CODING
BASIC PART NO. CONDITION CODE
19850 08
OASIS CODES: 208000, 208300, 208999