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Expansion Block/Orifice Tube: Service and Repair

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number
Spring Lock coupling Disconnect Tool (5/8 inch) 412-038 (T83P-19623-C)
Spring Lock Coupling Disconnect Tool (1/2 inch) 412-027 (T81P-19623-G2)







REMOVAL
1. Discharge the refrigerant from the A/C system following the recommended service procedures. Observe all safety precautions. Discharging and Recovery
2. Disconnect the condenser to evaporator tube from the A/C evaporator core using Spring Lock Coupling Disconnect Tool 412-038 (T83P-19623-C) (5/8 inch). Cap the condenser to evaporator tube to prevent the entrance of dirt and excessive moisture.
3. Pour a small amount of clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B into the evaporator core inlet tube to lubricate the tube and O-ring seals during removal of the A/C evaporator core orifice from the evaporator core tube.
4. Engage the Fixed Orifice Tube Tool 412-D001(D80L-19990-A) or equivalent with two tangs on the A/C evaporator core orifice. Do not twist or rotate the A/C evaporator core orifice in the A/C evaporator core tube as it may break off.
5. Hold the T-handle of the Fixed Orifice Tube Tool 412-D001(D80L- 19990-A) or equivalent to keep it from turning and run the nut on the tool down against the A/C evaporator core tube until the A/C evaporator core orifice is pulled from the tube.
a. To remove a broken A/C evaporator core orifice, insert the screw end of the Broken Orifice Tube Extractor 412-D002(D8OL-19990-B) or equivalent into the A/C evaporator core tube and thread the screw end of the tool into the brass tube in the center of the A/C evaporator core orifice. Pull the A/C evaporator core orifice from the A/C evaporator core tube.

NOTE: If the A/C evaporator core orifice breaks in the A/C evaporator core tube, remove it from the tube with Broken Orifice Tube Extractor 412-D002(D8OL-19990-B) or equivalent as follows:

b. If only the brass center tube is removed during Step a., insert the screw end of Broken Orifice Tube Extractor 412-D002(D80L-19990-B) or equivalent into the A/C evaporator core tube and screw the end of the tool into the A/C evaporator core orifice body. Pull the A/C evaporator core orifice body from the A/C evaporator core tube.

INSTALLATION
1. Lubricate the O-ring seals on the A/C evaporator core orifice liberally with clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B.
2. Place the A/C evaporator core orifice in the Fixed Orifice Tube Tool 412-D001(D80L-19990-A) or equivalent and insert it into the A/C evaporator core tube until it is seated at the stop.
3. Remove the remover/replacer tool from the A/C evaporator core orifice.
4. Using new O-ring seals lubricated with clean Motorcraft refrigerant oil YN- 12c or equivalent meeting Ford specification WSH-M1C231-B, connect the condenser to evaporator tube to the A/C evaporator core inlet tube.
5. Leak-test, evacuate and charge the system following the recommended service procedures. Observe all safety precautions.
6. Check the system for proper operation.
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