I am in the midst of replacing the core. Let me tell all of you that this has been the worst project I've ever attempted on my truck. I printed off Quintin's instructions and followed along in my Hayne's manual but I still ended up taking out stuff I didn't need to because that stupid dashboard would not come out. I think I ended up spending 8-9 hours just taking it out. I then spent another 4 hours taking out the heater core ( I followed Quintin's advice here and sawzawed out the old one ) but then lost o-rings so had to run to the auto store, then I broke one of the plastic retainers for the heater hose, ended up getting one at Ford, then I remembered I needed to get insulation tape. By the time I spent 1/2 hour struggling to get the heater hose on the 4 hours had elapsed and it was pitch dark, time to call it a night.
Now I scheduled myself Sunday afternoon, and a vacation day for today to get it done. Now I will have to take a sick day so I can put it back together. Hopefully it doesn't take quite as long and I don't forget where something goes, especially wires and connectors.
I literally took out just about everything in the dash. The outer dash is out along with every electric component found in the dashboard. All thats really still in it are the HVAC venting, wiring and the steering wheel (although parts of it are out as well).
This really has turned into a much bigger project than I anticipated. For anyone who can afford to have it done when the time comes I strongly urge you to do it. I cannot afford it right now since I have sooo many items needing replaced already: shocks, lower suspension bushings, at least 1-2 tires, air conditioner compressor, cruise control and 4x4. I can do the shocks and maybe the cruise but everything else I'll have to save money to have done. Thats the only reason I tackled this job.

 

It's a labor intensive job, no doubt. But at least throughout all the trials and tribulations, you learned from it, didn't ya? And your truck's fixed up too. Sounds like a win to me.

 

Labor intensive isn't even the word! I've had mine changed out three times. The last two I helped do, and it was no easy task. I'm ready to buy another truck if it goes out again. It is one of the hardest tasks to do on the truck.

 

They ain't so bad after you've done several back to back. When I'm on my A-game and everything goes as planned, I can usually do 'em in about 4-5 hours, that's with power tools and a lift though.

 

If I were using power tools and had a couple under my belt I'm sure I could do it in a day. This time I've kinda just stumbled through it. Even with all the warnings out there I wasn't prepared for the difficulty of this job. I just hope everything works and the truck runs when I'm finished.

 

Whenever I do one of those projects where I know I'll never remember where/how all the parts go back together, I use a digital camera to snap photos to use for reference when reassembling.

Jim

 

I thought about that after I had it all apart. Wish I had done it.
I got it all back together, but when I started it up one of the heater hoses was leaking really bad at the disconnect. So I took it apart to find that all my o-rings had fallen out when I was fighting with it to put it on. So back to the store for o-rings. Got it back on no problem and no leakage now.
The dashboard was something else to get back together. I need to go back and take the speedo back out because the gear selector fell down a little bit and now sits at an angle. I did have one connector that I could not find a mate too. Its down along the steering shaft below a plate that has 3 small connectors. This connector is a medium sized one and has 5 pins in it with room for 6, I believe the connector is white. Its long enough to reach the backside of the plug in for the diagnostic. I'm thinking it needs plugged in somewhere because the only problem I have now is it runs rough at idle.

And of course I had several left over bolts, but the dash is not loose at all.

All in all this was a HUGE project that I should have scheduled more time for. I did save a whole lot of money by doing it myself and I learned allot by doing it.

Also, I am happy to report I once again have heat, and it comes out the vents with no noise at all.