FORD: 1989-1993 MUSTANG, THUNDERBIRD 1989-1994 TAURUS, TEMPO
LINCOLN: 1989-1994 CONTINENTAL MERCURY: 1989-1993 COUGAR
1989-1994 SABLE, TOPAZ
This TSB article is being republished in its entirety 7. Remove four (4) cluster opening finish panel to correct the TSB number referred to in the Note retaining screws and pull panel rearward.
text of the Thunderbird/Cougar evaporator core
8. Remove speed control module, if so equipped replacement procedure.
(two (2) screws).
Because the instrument panel area on 1994
9. Remove lower steering column shroud (five (5) Thunderbird/Cougar models was reconfigured for air
screws).
bags, it is recommended that the entire instrument
panel be removed to facilitate replacement of the 10. Disconnect all steering column electrical evaporator core and housing assembly. connections: ignition, washer/wiper, turn signal,
key warning buzzer and speed control. On
ISSUE
console automatic transmission shift, remove A procedure has been developed for replacing the interlock cable retaining screw and disconnect evaporator core without removing the instrument cable from steering column.
panel from the vehicle. Following this procedure will
reduce the time required to replace an evaporator 11. Loosen, but do not remove, two (2) nuts and
core. two (2) bolts retaining steering column to
support bracket and remove upper shroud.
ACTION
12. Loosen steering column to intermediate shaft Loosen the instrument panel from the cowl by
clamp connection and remove bolt or nut.
pulling the right end of the instrument panel rearward. This provides enough clearance to
13. Remove two (2) nuts and two (2) bolts retaining remove the evaporator case from the vehicle. A
steering column to support bracket.
service procedure for each of the vehicles listed
above is presented in this article. Refer to the 14. Pry open steering column shaft in area of following procedures for service details. clamp on each side of bolt groove with steering
column locked. Open enough to disengage TEMPO/TOPAZ EVAPORATOR CORE
shafts with minimal effort. Remove column.
REPLACEMENT
15. Inspect two (2) steering column bracket clips for 1. Disconnect battery ground cable.
damage. If clips have been bent or excessively distorted, they must be replaced.
2. Raise vehicle.
16. Remove four (4) screws retaining cluster and 3. Disconnect speedometer cable at transaxle.
carefully pull rearward enough to disengage
4. Lower vehicle. speedometer cable. Loosely install two (2)
screws to retain instrument cluster during 5. Remove two (2) cover retaining screws at
instrument panel removal.
bottom of steering column opening and snap
cover out. 17. Remove left A-pillar garnish molding (five (5)
screws).
6. Remove snap in lower cluster finish panel(s)
(Topaz LS is one piece, all others, two pieces) 18. Remove right A-pillar garnish molding (five (5) to expose two (2) screws and two (2) bolts. screws).
19. Remove left kick panel. 35. Remove the evaporator core from the case following the procedure in the appropriate 20. Remove one (1) instrument panel-to-steering service manual for cutting the top out of the
column support bracket retaining nut, accessible case.
through steering column opening.
36. Install the new core in the case and seal the 21. Remove two (2) lower instrument panel-to-cowl top of the case as outlined in the appropriate
side retaining screws (RH and LH side). service manual.
22. Remove two (2) instrument panel vertical brace 37. Install the evaporator case in the vehicle by retaining nuts located on the LH side of glove reversing the removal procedure.
compartment.
23. Gently pull instrument panel away from RH side NOTECHECK THE OPERATION OF ALL COMPONENTS
of cowl panel. AFTER ASSEMBLY IS COMPLETED.
24. Drain the coolant from the radiator into a clean TAURUS/SABLE EVAPORATOR CORE
container. REPLACEMENT
25. Discharge the refrigerant from the A/C system, 1. Disconnect battery ground cable.
following the recovery procedure.
2. Remove radio cluster as outlined in the Service
CAUTION Manual, Section 15-01.
OBSERVE ALL SAFETY PRECAUTIONS
3. Remove two (2) bolts and remove the steering 26. Disconnect the heater hoses from the heater column opening cover from under steering
core. Plug the heater core tubes or blow any column.
coolant from the heater core with low pressure
air. 4. Remove sound insulators from under steering
column.
27. Disconnect the liquid line and the suction
accumulator/drier inlet tube from the evaporator 5. Remove three (3) screws retaining lower core at the dash panel. Cap the refrigerant steering column shroud and remove shroud.
lines and evaporator core to prevent the
6. Remove two (2) bolts and steering column entrance of dirt and excess moisture.
reinforcement from under steering column.
28. Disconnect the wire harness connector from the
7. Disconnect all electrical connections from blower motor resistor.
steering column switches.
29. Remove one (1) screw retaining the bottom of
8. Remove four (4) nuts retaining steering column the evaporator case to the cowl panel.
support brace, disconnect PRNDL cable 30. Remove the instrument panel brace from the (column shift) and lower steering column.
cowl top panel.
9. Disconnect park brake release cable from park 31. In the engine compartment, remove two (2) brake and disconnect ignition switch wiring
nuts retaining the evaporator case to the cowl connector.
panel.
10. Remove instrument cluster finish panel and 32. Loosen the sound insulator from the cowl top disconnect all instrument cluster finish panel
panel in the area around the air inlet opening. electrical connections.
33. Remove the two (2) screws retaining the 11. Remove four (4) retaining screws from support bracket and the brace to the cowl top instrument cluster and...
panel.
a. disconnect speedometer cable (if equipped), 34. Pull the right end of the instrument panel away
b. disconnect wiring and remove instrument from the cowl and remove the evaporator case
cluster.
from the vehicle. Place the evaporator case on a work bench.
12. Remove one (1) bolt at steering column CAUTION
opening attaching instrument panel to brace. OBSERVE ALL SAFETY PRECAUTIONS 13. Remove one (1) instrument panel brace 31. Disconnect the liquid line and the suction
retaining bolt (under the radio area). accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines 14. Remove sound insulator under glove and evaporator core to prevent the entrance of
compartment by removing two (2) push nuts dirt and excess moisture.
that secure insulator to studs on the evaporator
case. 32. Disconnect heater hoses from heater core
tubes and plug hoses with suitable 5/8″ (16mm) 15. Remove three (3) screws attaching glove and 3/4″ (19mm) plugs. Cap heater core tubes
compartment assembly to instrument panel and to prevent coolant loss from heater core during
remove door assembly. removal of evaporator core.
16. Remove LH and RH cowl side trim panels. 33. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment.
17. Disconnect electrical connections at RH cowl
side. 34. Remove screw holding instrument panel shake
brace to evaporator case and remove 18. Remove three (3) screws retaining instrument
instrument panel shake brace.
panel to cowl top panel.
35. Remove two (2) screws retaining floor register 19. Remove one (1) screw at instrument panel RH
and rear seat duct to bottom of evaporator side.
case.
20. Remove two (2) instrument panel-to-center
36. Remove three (3) nuts retaining evaporator console nuts.
case to cowl panel in engine compartment.
21. Remove cup holder and shift lever opening
37. Remove two (2) screws retaining support retaining screw.
brackets to cowl top panel.
22. Remove shift lever rearward.
38. Carefully pull the right end of the instrument 23. Remove shift lever opening cover (snaps out). panel away from the cowl panel, pull the
evaporator case away from the cowl and 24. Remove eight (8) console-to-floor bracket remove the evaporator case from the vehicle.
retaining screws (the two (2) rear screws are Place the evaporator case on a work bench.
under the mat in the rear storage bin).
39. Remove the evaporator core from the case 25. Disconnect all necessary electrical connections following the procedure in the appropriate
and remove console. service manual.
26. Remove two (2) nuts and two (2) screws 40. Install the new core in the case and seal the retaining instrument panel to cowl panel behind top of the case as outlined in the appropriate
center console. service manual.
27. Remove one (1) screw at instrument panel LH 41. Install the evaporator case in the vehicle by
side. reversing the removal procedure.
28. Gently pull instrument panel away from RH side NOTE of cowl panel.
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.
29. Place a drain pan or suitable container under heater hose connections at the cowl panel.
CONTINENTAL EVAPORATOR CORE REPLACEMENT
30. Discharge refrigerant from the A/C system at service access gauge port valve located in
1. Disconnect battery ground cable.
suction line, following the recovery procedure.
2. Remove RH finish molding by pulling up to unsnap six (6) clips and disconnect wiring.
3. Open glove compartment door and depress 22. Remove LH and RH cowl side trim panels.
both sides of glove compartment inward and
23. Disconnect electrical connections at RH cowl lower glove compartment door toward floor.
side panel.
4. Remove LH finish molding by pulling up to
24. Remove two (2) lower screws at instrument unsnap six (6) clips.
panel, one at each end.
5. Remove four (4) push pins from RH and LH
25. Remove three (3) upper instrument panel lower insulators. Remove insulators .
retaining screws and gently pull instrument 6. Remove five (5) screws retaining lower panel away from RH side of cowl panel.
instrument panel steering column cover and
26. Place a drain pan or suitable container under remove cover.
heater hose connections at the cowl panel.
7. Remove four (4) screws retaining lower
27. Discharge refrigerant from the A/C system at instrument panel steering column reinforcement.
service access gauge port valve located on Remove reinforcement.
suction line, following the recovery procedure.
8. Remove four (4) nuts and absorber assembly.
CAUTION
9. Remove tilt wheel lever. OBSERVE ALL SAFETY PRECAUTIONS.
10. Remove two (2) screws retaining lower steering 28. Disconnect the liquid line and the suction column shroud. Remove lower steering column accumulator/drier inlet tube from the evaporator
shroud. core at the cowl panel. Cap refrigerant lines
and evaporator core to prevent the entrance of 11. Disconnect PRNDL cable and all steering dirt and excess moisture.
column electrical connections.
29. Disconnect heater hoses from heater core 12. Remove four (4) nuts retaining steering column. tubes and plug hoses with suitable 5/8″ (16mm)
Lower steering column. and 3/4″ (19mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during 13. Remove screw, at steering column opening,
removal of evaporator core.
retaining instrument panel to brake pedal
support. 30. Disconnect vacuum supply hose from in-line
vacuum check valve in engine compartment.
14. Remove two (2) screws under ash receptacle
which retain instrument panel to evaporator 31. Remove screw holding instrument panel shake
case. brace to evaporator case and remove
instrument panel shake brace.
15. Remove headlamp switch knob.
32. Remove two (2) screws retaining floor register 16. Remove five (5) screws from instrument cluster
(or rear seat adapter) to bottom of evaporator opening finish panel and remove panel.
case.
17. Remove four (4) screws retaining instrument
33. Disconnect the vacuum line, electrical cluster. Disconnect electrical connectors.
connections and aspirator hose from the 18. Remove three (3) screws to remove glove evaporator case.
compartment assembly.
34. Remove three (3) nuts retaining evaporator 19. Remove two (2) screws from instrument panel case to cowl panel in engine compartment.
to cowl top brace and one (1) screw from
35. Remove two (2) screws retaining support passenger air bag support bracket.
brackets to cowl top panel.
20. Remove both side demister grilles by snapping
36. Carefully pull the right end of the instrument out to release.
panel away from the cowl panel, pull the 21. Remove two (2) screws and remove center evaporator case away from the cowl and
defrost grille. remove the evaporator case from the vehicle.
Place the evaporator case on a work bench.
37. Remove the evaporator core from the case 14. Disconnect wiring, heater and A/C vacuum lines following the procedure in the appropriate and control cables through glove compartment
service manual. opening.
38. Install the new core in the case and seal the 15. Remove two (2) screws at RH side retaining top of the case as outlined in the appropriate instrument panel to cowl side.
service manual.
16. Remove two (2) screws at LH side retaining 39. Install the evaporator case in the vehicle by instrument panel to cowl side.
reversing the removal procedure.
17. Remove RH and LH finish panel by pulling up
NOTE to disengage snap-in retainers, three (3) on RH
side and four (4) on LH side.
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.
18. Remove RH and LH roof rail trim panels.
THUNDERBIRD/COUGAR EVAPORATOR CORE
19. Remove four (4) screws retaining instrument REPLACEMENT
panel to cowl top.
NOTE 20. Gently pull instrument panel away from RH side
REFER TO TSB 94-2-12 IF WATER DRIPS FROM
of cowl panel.
THE FLOOR DUCTS
21. Place a drain pan or suitable container under 1. Disconnect battery ground cable.
heater hose connections at the cowl panel.
2. Remove steering column lower trim cover.
22. Discharge refrigerant from the A/C system at (Remove three (3) screws at bottom, one (1)
service access gauge port valve located on screw LH side and pull to disengage five (5)
suction line, following the recovery procedure.
snap-in retainers across top).
CAUTION 3. Remove steering column lower opening
OBSERVE ALL SAFETY PRECAUTIONS.
reinforcement. Six (6) screws retain
reinforcement to instrument panel. 23. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator 4. Remove steering column upper and lower
core at the cowl panel. Cap refrigerant lines shrouds.
and evaporator core to prevent the entrance of dirt and excess moisture.
5. Disconnect wiring from steering column.
24. Disconnect heater hoses from heater core 6. Remove shift interlock switch.
tubes and plug hoses with suitable 5/8″ (16mm) 7. Disconnect steering column lower universal and 3/4″ (19mm) plugs. Cap heater core tubes
joint. to prevent coolant loss from heater core during
removal of evaporator core.
8. Support steering column and remove four (4)
nuts retaining column to support. Remove 25. Disconnect vacuum supply hose from in-line
column from vehicle. vacuum check valve in engine compartment.
9. Remove one (1) nut retaining LH side of 26. Working under the hood, remove three (3) nuts instrument panel to parking brake bracket. retaining the evaporator case to the cowl panel.
10. Remove RH and LH side cowl trim panels. 27. Inside the passenger compartment, remove the screw attaching the evaporator case support 11. Disconnect electrical connections at RH cowl
bracket to the cowl top panel.
side.
28. Remove one (1) nut retaining the bracket below 12. Remove two (2) instrument panel-to-floor tunnel
the evaporator case to the cowl panel.
nuts.
13. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor.
29. Carefully pull the right end of the instrument c. Radio with graphic equalizer (one unit).
panel away from the cowl panel, pull the • Combination a: Use a small screwdriver evaporator case away from the cowl and and pry radio cover finish panel out of remove the evaporator case from the vehicle. console.
Place the evaporator case on a work bench. • Combinations b and c: The radio must be removed first. Refer to Service Manual, 30. Remove the evaporator core from the case
Section 15.01, for procedure.
following the procedure in the appropriate service manual.
9. Open glove compartment door and depress both sides of glove compartment inward and 31. Install the new core in the case and seal the
lower glove compartment door toward floor.
top of the case as outlined in the appropriate service manual.
10. Remove four (4) console bracket retaining screws. Remove console from vehicle.
32. Install the evaporator case in the vehicle by reversing the removal procedure.
11. Remove three (3) bolts retaining steering column opening cover and reinforcement panel.
NOTE
Remove cover.
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.
12. Remove steering column opening reinforcement by removing two (2) bolts.
MUSTANG EVAPORATOR CORE REPLACEMENT
13. Remove two (2) bolts retaining steering column 1. Disconnect battery ground cable.
opening reinforcement and remove 2. Remove two (2) access covers at rear of reinforcement.
console (snaps out) to gain access to arm rest
14. Remove six (6) steering column retaining nuts, retaining bolts.
two (2) retaining the hood release mechanism 3. Remove armrest-to-floor bracket retaining bolts and four (4) retaining column to lower brake
and remove armrest assembly (snaps out of pedal support. Lower steering column to floor.
console).
15. Remove steering column upper and lower 4. Remove gearshift opening finish panel (snaps shrouds and disconnect wiring from
out). On vehicles equipped with manual multi-function switch.
transmissions, shift boot is attached to bottom
16. Remove steering column through-bolt and nut of finish panel. Remove shift knob and slide
on engine side of cowl panel. Remove steering boot and finish panel up to shift lever to
column from vehicle.
remove.
17. Remove brake pedal support nut.
5. To remove top finish panel, position emergency brake lever in the UP position. Remove four (4)
18. Snap out defroster grille.
retaining screws and lift panel up. Disconnect
necessary wire connectors. 19. Remove screws from speaker grilles. Snap out speaker covers.
6. Remove two (2) console-to-rear floor bracket
retaining screws. 20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels.
7. Insert a small screwdriver into two (2) notches
at bottom of front upper panel and snap out. 21. Remove LH and RH cowl side trim panels.
8. There are three (3) combinations of radio cover 22. Disconnect electrical connections at RH cowl
finish panels: side panel.
a. Radio opening cover plate with storage bin 23. Remove cowl side retaining bolts, (one at each
(radio delete option). end).
b. Radio with storage bin. 24. Remove five (5) cowl top attaching screws.
25. Gently pull instrument panel away from RH side 36. Remove the evaporator core from the case of cowl panel. Disconnect speedometer cable, following the procedure in the appropriate air conditioning controls and wire connectors. service manual.
26. Place a drain pan or suitable container under 37. Install the new core in the case and seal the heater hose connections at the cowl panel. top of the case as outlined in the appropriate
service manual.
27. Discharge refrigerant from the A/C system at
service access gauge port valve located on 38. Install the evaporator case in the vehicle by suction line, following the recovery procedure. reversing the removal procedure.
NOTE NOTE
OBSERVE ALL SAFETY PRECAUTIONS. CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED
28. Disconnect the liquid line and the suction
accumulator/drier inlet tube from the evaporator OTHER APPLICABLE ARTICLES: 94-2-12 core at the cowl panel. Cap refrigerant lines SUPERSEDES: 94-3-3
and evaporator core to prevent the entrance of WARRANTY STATUS: Eligible Under The
dirt and excess moisture. Provisions Of Bumper To
Bumper For 1992/94
29. Disconnect heater hoses from heater core Vehicles And 1991 Lincolns, tubes and plug hoses with suitable 5/8″ (16mm) Basic Warranty Coverage and 3/4″ (19mm) plugs. Cap heater core tubes For All Other Models And to prevent coolant loss from heater core during 1989/90 Major Component
removal of evaporator core. Warranty Coverage
OPERATION DESCRIPTION TIME 30. Remove screw holding air inlet duct and blower
940808A Replace Evaporator Core 4.5 Hrs.
housing assembly support brace to cowl top
(1989-94 Tempo/Topaz) panel.
940808B Replace Evaporator Core 3.2 Hrs.
31. Disconnect the vacuum line (black), from in-line (1989-93 Mustang)
vacuum check valve in engine compartment. 940808C Replace Evaporator Core 4.0 Hrs.
(1989-94 Taurus/Sable)
32. Remove three (3) nuts retaining evaporator 940808D Replace Evaporator Core 3.8 Hrs.
case to cowl panel in engine compartment. (1989-94
Thunderbird/Cougar) 33. Inside the passenger compartment, remove two
940808E Replace Evaporator Core 4.1 Hrs.
(2) screws retaining evaporator case support
(1989-94 Continental) brackets to cowl top panel.
DEALER CODING
34. Remove one screw retaining bracket below CONDITION
evaporator case to cowl panel. BASIC PART NO. CODE
19860 01
35. Carefully pull the right end of the instrument OASIS CODES: 208000, 208200, 290000 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.
