Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Heater Core

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Removal & Installation



The combination coil is used only with the optional rear heater/air conditioning housing assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. If equipped, remove the rear bench seat.
  8.  
  9. Raise and safely support the rear of the vehicle.
  10.  
  11. Disconnect the underbody plumbing from the rear heater/air conditioning housing plumbing connections. Plug all of the openings to prevent contamination.
  12.  
  13. Remove the rear heater/air conditioning housing-to-underbody panel screw.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the 3 cover-to-rear heater/air conditioning housing screws and the cover.
  18.  
  19. From the rear heater/air conditioning housing assembly, perform the following procedures:
    1. Remove the vertical duct.
    2.  
    3. Remove the horizontal duct.
    4.  
    5. From behind the unit, remove the ground wire eyelet-to-left side panel strainer screw.
    6.  

  20.  
  21. Disassemble the rear heater/air conditioning housing assembly by performing the following procedure:
    1. Lift both relay wiring harness connectors upward and disconnect them from the mounting tabs located at the rear of the housing.
    2.  
    3. Disconnect the wiring connectors from the blower motor and the rear mode control motor.
    4.  
    5. Disconnect the blower motor cooling tube from the lower housing nipple.
    6.  
    7. Remove the control cable from the water valve.
    8.  
    9. Remove the rear inboard corner lower housing-to-upper housing clip.
    10.  
    11. Remove the upper-to-lower housing screws.
    12.  
    13. Remove the upper housing.
    14.  

  22.  
  23. Remove the combination coil from the lower heater/air conditioning housing.

    Click image to see an enlarged view

    Fig. View of the rear heater/air conditioning housing assembly plumbing plate

    View of the rear heater/air conditioning housing assembly plumbing plate

    Click image to see an enlarged view

    Fig. View of the rear heater/air conditioning housing assembly

    View of the rear heater/air conditioning housing assembly

    Click image to see an enlarged view

    Fig. View of the combination coil

    View of the combination coil
  24.  

To install:

  1. Install the combination coil to the lower heater/air conditioning housing.
  2.  
  3. Assemble the rear heater/air conditioning housing assembly by performing the following procedure:
    1. Install the upper housing.
    2.  
    3. Install the upper-to-lower housing screws and torque to 20 inch lbs. (2.2 Nm).
    4.  
    5. Install the rear inboard corner lower housing-to-upper housing clip.
    6.  
    7. Install the control cable to the water valve.
    8.  
    9. Connect the blower motor cooling tube to the lower housing nipple.
    10.  
    11. Connect the wiring connectors to the blower motor and the rear mode control motor.
    12.  
    13. Connect them to the mounting tabs located at the rear of the housing.
    14.  

  4.  
  5. At the rear heater/air conditioning housing assembly, perform the following procedures:
    1. Behind the unit, install the ground wire eyelet-to-left side panel strainer screw.
    2.  
    3. Install the horizontal duct.
    4.  
    5. Install the vertical duct.
    6.  

  6.  
  7. Install the 3 cover-to-rear heater/air conditioning housing screws and the cover.
  8.  
  9. Raise and safely support the rear of the vehicle.
  10.  
  11. Install the rear heater/air conditioning housing-to-underbody panel screw.
  12.  
  13. Connect the underbody plumbing to the rear heater/air conditioning housing plumbing connections.
  14.  
  15. Lower the vehicle.
  16.  
  17. If equipped, install the rear bench seat.
  18.  
  19. Refill the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate and charge the air conditioning system refrigerant.
  24.  
  25. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  26.  

 
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