After dealing with lack of heat, no heat, doing reverse flushes, lots of heat and then no heat again, all ending with...
ugh oh. Now, it's leaking...
Damn.
I decided to replace the heater core. I bought a replacement from Ford and got an older service manual online (DVD version).
If I ever did it again or was asked to provided advice, I now know all the little tricks that weren't addressed in the manual. Nothing earth shattering, just a few small items that would have made the project faster.
Although the new heater core is installed in the housing, I haven't mounted it yet. But, once I put on the new o-rings on the AC lines and test/confirm that system doesn't have any leaks, I'll start to put everything back together.
I attached some of the pictures I took. I took a lot of pictures and marked up many of the PDF printouts just in case I forgot some of the details and needed a reminder where the screws, parts, etc. are supposed to go.
The funniest part about this project was my wife's reaction when she saw my progress after the first day taking things apart. BTW, it's her car. LOL.
Luckily, we have a few cars so this one can sit in the garage until it's done.
BTW, my wife really enjoys this car. This is just a minor inconvenience.
