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First Gen Heater Core Help


rvaughn801

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My heater smells really bad, and I have taken it apart far enough to reach inside to the bottom of the plastic heater box and feel antifreeze. So it needs to come out.The issue I have is how to get to it. There is small panel that comes off easily so I can see part of the core. I can also see a vacuum actuate flap that closes off air flow to the core.At this point, is the best plan of action to remove major pieces of plastic and/or dash to get at this? Or is that needed? I haven't found a step by step removal how-to for the 1st Gen D250. But how-tos for other cars talk about removing a small rectangle of heater core box for access, then riveting a cover over the hole. Has anyone done this?Thanks in advance for your help.

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Thanks for the help. I got a little farther last night, and will get started again once I get some presents wrapped :)

Fortunately I have another car to drive to work tomorrow.

The heater box is still not free, so I may have missed a fastener on the engine side.

Once I can pull the box away from the firewall, can I get the core through the opening under the center of the dash, or does the top of the box need to come up and off?

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Again, thank you Michael.

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Dumping the freon would not be a big deal, as the A/C hasn't worked in 10 years. It is still and R12 system. I will prod the valve with a screwdriver and see if anything comes out.This truck originally came (in 1989) without A/C, and A/C was added by a dealer in 1992. Does that make a difference? You can see in the pics the sloppy cuts in the dash for A/C vents. It was a Canadian truck, with metric speedometer and no cruise control.This is the 2nd heater core that has gone bad. A shop replaced the first one for me, for $90 labor (I supplied the part). They didn't mention evacuating the freon.The part I bought has a lifetime warranty, so I wanted to do it myself. That, and the face that this core only lasted 5 years, so I felt like I need to know how to do it (if only Cummins made the rest of the truck!)I think I've already asked, but any chance I could cut an access hole and patch with rivets? I would like to get this back on the road. I apologize for trying to take short cuts, but this is a busy time of year. Thanks again for all the help.

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