If I have to replace the heater core, is there an easier way the pulling the dash, steering wheel, and air box? Seems like a lot of work for a $50 part. If not, do I really have to disconnect/drain the A/C to get the heater core out? Rather not do that if I can avoid it.

thanks.

 

Unfortunately, no. There is no easier way. You do have to discharge the a/c, drain the cooling system (or at least pinch off the heater hoses), and remove the dash.

Putting the truck together, the HVAC went in first.

 

That is right. The heater core is all the way between the dash board and the fire wall. Never did it in a Van but in my 93 Jeep Grand Cherokee and is a LOT of work. You will have to (DISCONNECT THE BATTERY NEGATIVE CABLE) lower the steering column and separate the dash board from the fire wall. A lot of small bolts and nuts, but considering that winter is almost here and you( and family, specially kids) might be breathing ANTIFREEZE fumes, I would start early in the morning, in a garage if possible, slowly, step by step. Some bolts go thru the fire wall and the nut is in the engine side. You have to start by removing the radio (there is probably a bolt behind it, then lower the column. Might be three or four screws by the windshield (inside in line with the VIN #), probably covered in plastic which is "clip in" Head under the dash, there should be a bolt by the corner on each side, once those are out, by moving the dash you may have an idea of where the rest are. Patience and don't pull hard. I really wish this helps. ANTIFREEZE FUMES ARE DANGEROUS. Good luck.

 

DAMN!!!! i dont wanna do this!!! but i have an anti freeze smell also. i was afraid it maybe this issue. i smell it more on low fan setting than on HOT high fan. with hot high fan setting i dont smell it at all.
is there an "access" hole to view into the casing that holds the core to see if there really is a leak?
just dont know if i have the patience and will to take the whole dang dash apart. you also say have to drain the AC to take apart?

 

There is no access hole either.

I suppose you could get a borescope and snake it in there though.

Yes, the a/c has to be discharged.

 

just chiming in that the labor involved in swapping a heater core saved me the trouble when searching for a quad cab. One guy was trying to tell me there was no leaks yet the smell and fogged window was present in the quad he was trying to offload. These days anymore it seems designers are trying harder and harder to complicate repairs for the diy'er.