The process generally involves these steps, but details may vary depending on the specific model and configuration of your truck:
1. Disconnect the Battery: This is crucial to prevent electrical shorts and injury.
2. Access the Evaporator: This usually requires removing a significant portion of the dashboard. This involves removing trim pieces, possibly the glove box, and potentially the entire instrument panel. This is time-consuming and requires patience and care to avoid breaking any plastic clips.
3. Recover Refrigerant: This is critical. You MUST use a refrigerant recovery machine to safely remove the refrigerant from the system before disconnecting any lines. Releasing refrigerant into the atmosphere is illegal and harmful to the environment.
4. Disconnect HVAC Components: This includes disconnecting hoses, electrical connectors, and vacuum lines associated with the evaporator. Carefully label everything to ensure proper reassembly.
5. Remove the Evaporator: This often involves removing the blower motor assembly and other components to gain access. The evaporator is usually located behind the dashboard, often behind the blower motor.
6. Install the New Evaporator: Carefully install the new evaporator, ensuring proper alignment and seating.
7. Reconnect HVAC Components: Reconnect all hoses, electrical connectors, and vacuum lines, ensuring a tight and secure connection. Double check your labeling.
8. Recharge the System: After reconnecting everything, you'll need to use a refrigerant charging machine to evacuate the system and recharge it with the correct amount and type of refrigerant.
9. Test the System: After recharging, thoroughly test the A/C system to ensure proper cooling and no leaks.
Tools you will likely need:
* Refrigerant recovery and charging machine
* Vacuum pump
* Various sockets, wrenches, and screwdrivers
* Torque wrench
* Panel removal tools
* Safety glasses and gloves
Strong Recommendation: Due to the complexity of this repair, and the potential for costly mistakes, it is strongly recommended that you take your 2003 Ford F-350 to a qualified automotive air conditioning specialist. They have the proper tools, knowledge, and experience to perform this repair safely and correctly. The cost of professional repair will likely be less than the cost of making mistakes during a DIY attempt.
