I've posted about this on some older threads on other forums, but I generally use this site the most, so I apologize if you've seen this same subject on others.

So I'm replacing my evaporator core. The dash is already pulled, heater and evaporator cores are already out. Had to cut the old evaporator to get it out. Problem is, I can't get the new one back in the truck. The instructions for the heater core replacement are thorough and awesome, but there is nothing for evap cores. Haynes Manual says to pull it out, and reverse to install, but it will not go back in. Do I need to remove the entire plenum? If so, how? I've found 4 nuts that are holding the plenum that I've removed, but it's still not coming off. So I'm stuck. Any suggestions are welcomed.

Where I currently am:


And here's my old core. Pretty filthy. No wonder my air sucked.

 

I have no idea. What year? That old one is nasty!

 

It's a 2002 XL. Yeah that old one is disgusting

 

Yes you have to remove the plenum, all the nuts should be under the hood area on firewall. Did you disconnect the A/C lines also?

 

Yep. All the lines are disconnected. Is there a nut near the drain hose or something that I just can't see, cuz that plenum is not coming out after removing the two nuts under the hood that I can see, as well as two in the cab that I've found.

 

I think there are two or three in the engine bay and then the same amount inside. Check the underside of the box if I recall correctly there may be one there. I have checked ALLDATA and it does not give a count as to how many just says to remove them all. When you are pulling on the plenum see if you can tell where it seems to be stuck and that should lead you to the bolt or nut you cannot seem to find. Usually it will be somewhat loose in the areas that you have removed the bolts and will seem as though it is stuck in one place more than any others.

 

I found it! I had to remove a brace as well, but I was able to pull the plenum just far enough out to get the core in. Took some pics of where the nuts and bolts are. Will post later. Thanks for your help

 

Your welcome