The old insulation on my evaporator box was falling apart. I had seen people use this Reflectix insulation to cover the box and help insulate it from engine heat. This product along with the 3M adhesive can be found at Lowes. The insulation was about $17 and the adhesive $10.

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 the reservoir. These can have a tendency to leak so you'll want to check to make sure it holds vacuum.

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 them.

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...

this screw/bolt is the problem..Ford in it's infinite wisdom has is attached to the box from the inside of the cab...

here is a shot of the screw/bolt from the inside..it's a 10mm.

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, but the coils on the evaporator were pretty clean.

here is the cover removed.

cover all cleaned up.

checked the reservoir for vacuum and it holds.

started cutting the insulation and covering the box.

tedious process and a bit of trial and error.

getting closer.

finished product. hopefully this should help keep some of the engine heat out of the ducts and help the A/C cool better.

you should clean out the cowl drains while you have the inner fender pulled. this one was clean..

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 bottom right corner, mine was pretty clean.

flushed from the back with water and blown with compressed air..looks good.

seems like this is the factory evap. I've never replaced since I bought the rig and that's almost 20 years.

added a few more pieces of insulation to the box, figured that would help improve the R value and keep the air cooler.

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 proximity to the exhaust, it made sense to insulate this as well.

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 help hold everything in place. I think a combination of the engine heat and the condensation will make the adhesive come off.

next step will be to see if it helps cool any better.

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 probably closer to 110..

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 take and a the A/C was blowing 65. so I'm seeing a drop of about 37 degrees. that's not too bad.