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Evaporator Box R&R

From 1992 Ford Bronco “Big '92” — documented by Jeremy Millrood.

30 photos
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1992 Ford Bronco - The old insulation on my evaporator box was falling apart. I had seen people use this Reflectix insulation to cover the box and help insula… 1992 Ford Bronco - Here is the box, you can see how filthy it is. You only need to remove the side that covers the evaporator. Disconnect the vacuum line from… 1992 Ford Bronco - there are about 6 screws that hold the cover on. some of them are in tough to reach places so you'll have to feel around the edges to find… 1992 Ford Bronco - A hand uses a socket wrench on a black plastic component, likely part of an automotive repair. 1992 Ford Bronco - Mounting bracket for a vehicle's evaporator box, showing dirt and wear. 1992 Ford Bronco - A screwdriver is used to access a component on the dirty underside of a vehicle. 1992 Ford Bronco - all of the screws are removed and so is the nut holding box to the firewall. I'm able to start separating the it..but it's stuck... 1992 Ford Bronco - this screw/bolt is the problem..Ford in it's infinite wisdom has is attached to the box from the inside of the cab... 1992 Ford Bronco - Close-up view of an automotive part, possibly an evaporator box, with visible wear and tear. 1992 Ford Bronco - here is a shot of the screw/bolt from the inside..it's a 10mm. 1992 Ford Bronco - once that was removed it took a bit of manipulation, but the cover finally came out and there is the evaporator. need to get another shot,… 1992 Ford Bronco - Close-up view of the evaporator box and surrounding engine components within a vehicle. 1992 Ford Bronco - here is the cover removed. 1992 Ford Bronco - Automotive HVAC evaporator housing shown with cleaning supplies and shop rags. 1992 Ford Bronco - cover all cleaned up. 1992 Ford Bronco - checked the reservoir for vacuum and it holds. 1992 Ford Bronco - started cutting the insulation and covering the box. 1992 Ford Bronco - tedious process and a bit of trial and error. 1992 Ford Bronco - getting closer. 1992 Ford Bronco - finished product. hopefully this should help keep some of the engine heat out of the ducts and help the A/C cool better. 1992 Ford Bronco - you should clean out the cowl drains while you have the inner fender pulled. this one was clean.. 1992 Ford Bronco - while I have everything pulled apart, I wanted to check the evaporator they can accumulate a lot of garbage. other then some crud in the bo… 1992 Ford Bronco - flushed from the back with water and blown with compressed air..looks good. 1992 Ford Bronco - seems like this is the factory evap. I've never replaced since I bought the rig and that's almost 20 years. 1992 Ford Bronco - added a few more pieces of insulation to the box, figured that would help improve the R value and keep the air cooler. 1992 Ford Bronco - I almost forgot about about the bottom of the box. this was the other half and it was also covered with the factory insulation. with it's p… 1992 Ford Bronco - bottom view. doubled up on the insulation here. I think that should work pretty well...I may still go back and add a couple of staples to h… 1992 Ford Bronco - Close-up view of engine bay components, including the AC accumulator and various hoses. 1992 Ford Bronco - Testing my A/C...it was over 101 yesterday. granted, that was in the sun..not sure what the heat index was. with the humidity, it was proba… 1992 Ford Bronco - set the system to Max A/C with the windows down and this was the best it would do.. so you figure an ambient temp of 102 outside, give or t…