Ford Pick-ups and Broncos 1987-1996 Repair Guide




  1. Discharge the refrigerant system using a certified recycling/recovery station (refer to Routine Maintenance ).
  3. Disconnect the refrigerant lines from the condenser using the proper spring lock tool shown in the accompanying illustration. Cap all opening immediately!

The fittings are spring-lock couplings and a special tool, T81P-19623-G, should be used. The larger opening end of the tool is for1/2in. discharge lines; the smaller end for3/8in. liquid lines. To operate the tool, close the tool and push the tool into the open side of the cage to expand the garter spring and release the female fitting. If the tool is not inserted straight, the garter spring will cock and not release. After the garter spring is released, pull the fittings apart.

  1. Drain the cooling system.

When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the upper radiator hose.
  3. Remove the bolts retaining the ends of the radiator upper support to the side supports.
  5. Carefully pull the top edge of the radiator rearward and remove the condenser upper support.
  7. Lift out the condenser.
  9. If a new condenser is being installed, add 1 fl. oz. (29.5 ml) of new refrigerant oil to the new condenser. Installation is the reverse of removal. Always use new O-rings coated with clean refrigerant oil on the line fittings. Evacuate, charge and leak test the system.