2nd Gen Ram Tech1994-2001 Rams: This section is for TECHNICAL discussions only, that involve the 1994 through 2001 Rams. For any non-tech discussions, please direct your attention to the "General discussion/NON-tech" sub sections.
I just replaced the a/c evaporator in my '98 1500. I can post detailed instructions that anyone can use to complete the job. I borrowed some a/c gauges and a vaccuum pump, otherwise I just used a few basic tools. It took about 3 hours to remove the box and about 1 1/2 hours to replace it and 1 hour to charge the system with 2 cans of 134a. I would do it again in a minute and you will save hundreds on labor!
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Ok here is how to replace your a/c evaporator and/or heater core.
1) Disconnect battery cable
2) Remove first screw on door sill both sides ( these are the pieces that hold your carpet down)
3) Remove kick panels and panel under steering wheel.
4) Remove two nuts holding up steering wheel.
5) Remove five screws where dash meets the windsheild.
6) Remove 2 bolts on the left and right side of the dash up against the side of truck (under kick panels)
7)Dashboard can now be pulled free toward seat.
8)On passenger side of dash tie rope or wire to flange where bolt went into side of truck and lift dash up
to expose fan box. Secure rope to handle on side of A-post
9) Remove vaccuum lines and unclip electrical connections. (Hint: temperature control cable has to be
removed with pliers by pulling straight up, removing the entire clip.)
10) Now the secret: there are two screws holding the box to the firewall on the inside (one has ground
wire attached.) The other is in the upper right hand corner facing up.
11)There are four nuts holding it from the engine side of the firewall (one nut is accessed by removing the
electircal panel on passenger side.) Remove all four nuts.
12)Remove heater hoses by removing clamps. Mine were stuck so I just cut the hoses and got new ones.
13)Release A/C freon from LP side with gages and disconnect A/C lines from firewall exit. ( This
requires a simple 5 dollar tool that disconnects fueland A/C connections.
14) The heater box will now come free!
15) There are several screws holding heater box together. It will come apart in two halves. Go ahead
and replace your heater core because you dont want to do this again in a month!
16) You may want to replace your accumulator as well (its fairly cheap)
17) Reassemble /reinstall box. Draw vaccuum on A/C system for 30 mins. recharge with 134a.
I do not have any pics but trust me you wont need 'em. This was a first time evap replacement for me and it went great. The comment about the heater hoses is right on too.... Mine were a b@&$ to get off and I had to end up just cutting them. It was well worth it just to getsome new hoses instead of fighting with them, wasting time. As far as I know this job will be the same for 95-01 Rams. Again, just print the instructions.... I made sure they were accurate.
My evaporator is being replaced at this moment...I just bought the truck on 6/29 from a used car dealer and the a/c wasn't working. they told me they charged it and it was all good to go (their big mistake) 3 days later when it was out of freon they had to repair it. The owner of the place called me today and sounded really depressed when he told me I was right that it was the evap. LMAO his mechanic was taking the dash apart as we spoke. best part is all the $$$$ is on them (for once I got lucky) I was going to have him replace my heater core while he was in there but at the last minute I changed my mind (just had a bad feeling about him doing it), if and when it goes I will do it myself