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Discussion Starter #1
Getting coolant smell in the car with heat on and a oily film on the windshield, I assume its the Heater Core right?

Has anyone replaced it without removing the dash?
 

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If my heater core goes bad, I will probably bypass it, and live without heat.

Replacing it looks like a gruesome job.
 

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If my heater core goes bad, I will probably bypass it, and live without heat.

Replacing it looks like a gruesome job.
It's not too bad, just time consuming.

I also swapped the dash, and since I have a 1991 XR7, I had to swap the wiring harnesses also.

By myself, it took about a day of work all told.

RwP
 

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The hardest part is finding a second pair of hands when it's time to move the dash.
When my heater core was replaced, the dash was cleverly lifted by putting a board underneath it with bottle jacks on both sides. Then it was carefully raised enough to gain access to the core.
 

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You guys use helpers?

I pulled my 1991 Cougar's dash by myself. And put the new one in by myself.

RwP
 

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Just got mine back together a week ago, was down almost 3 weeks.Bought a core at Napa what a POS,took it back and had a radiator shop took a week to build me a good one.Now the original radiator developed a leak and power steering just started leaking.250k miles I guess its time.Had the wife help me pull the dash and steering column .
 

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Just got mine back together a week ago, was down almost 3 weeks.Bought a core at Napa what a POS,took it back and had a radiator shop took a week to build me a good one.Now the original radiator developed a leak and power steering just started leaking.250k miles I guess its time.Had the wife help me pull the dash and steering column .
To prevent electrolysis in your cooling system, run a ground wire from one of the heater core nipples to an appropriate location.
 

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Discussion Starter #11
Getting ready to finally do this, where's the best place to get Aluminum wire? Odd for me to go looking for Aluminum over Copper but in this cause I see the need. Also anyone see a problem soldering the wire to the core as opposed to using a hose clamp, I have Ag ,Pb and Pb free ?
 

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Getting ready to finally do this, where's the best place to get Aluminum wire? Odd for me to go looking for Aluminum over Copper but in this cause I see the need. Also anyone see a problem soldering the wire to the core as opposed to using a hose clamp, I have Ag ,Pb and Pb free ?
Solder, brazed, or welded; it should all be the same for corrosion resistance, as a ~zero resistance connection.

(Unless someone sux at making them, lol.)

I'd solder it; and if it's soldered, copper or aluminum won't matter. I'd wash off the flux, after, tho.

I'd use lead solder, it's more durable near a battery; silver is great, it makes it stick really well, but high silver causes issues in weather.

As long as everything is connected together, it won't corrode.
 

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Discussion Starter #13
That was no fun at all
 

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Discussion Starter #15
Still have to finish up, all the aftermarket wiring caused a delay.
 
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