Join Date: Nov 2009
my_nightmare is offline
HOW TO: 92 s10 heater core removal (May work on other years as well)
I've been doing a bunch of these tutorials for a friend of mine and thought that maybe a few here might like them as well. I am doing these from memory, So please no flame me if I got anything wrong. Now this is the way I was taught to do this job. Your way may be different. So here goes....
92 s10 heater core removal
#1 and #2 Phillips screwdriver
1/4 drive ratchet
6" 1/4 drv extension
12" 1/4 drv extension
1/4" brokeneck swivel for 1/4"drv
9/32" 1/4 drv socket
10 MM 1/4 drv socket
8 MM or 5/16" 1/4 drv socket
15mm 3/8 drv socket
6" extension 3/8
couple of shop lights and/or a good strong flash light
A box of ziploc sandwich bags
A sharpie marker
A small ratchet strap or a long bungie cord. (For holding the dash up and out of the way.)
Starting this JOB...
1: open hood
2: drain cooling system
3: locate and remove hoses from heater core
4: using air, blow out old coolant out of heater core (ya dont want it pouring out in your floor inside- plug the core lines when done.)
5: remove the 9/32 screw holding the clamp to heater core lines and then remove clamp
6) Disconnect negative cable from battery
(NOTE: your done on the outside for now...)
(Note: I am uninstalling the dash and hanging it out of the way..., your way may be different.)
(in future reference from here on in, if you see a ">" it means to BAG THE SCREWS/BOLTS AND MARK THE BAG!!)
1. Undo all hush covers from under dash using a 9/32 and the 10mm. ">" mark them HUSH COVER SCREWS (3 panels-maybe 4)
2. The kick panels need to be removed next.. ">" mark them kick panel screws
3. On driver side. Locate the cable going to the emergency brake.(the emerg release cable) and disconnect it
4. Remove all the phillip head screws from all the dash panels">" MARK THESE DASH PANELS
5. Remove the panel from under steering column now
6. Look under dash and locate on both corner sides of truck, the 10mm bolts going straight up towards dash top…, remove them and bag them(keep this bag near.., more to come…) Locate in the middle a 10mm that is bolted to a wire loop bracket. Look at right side of steering column, there is another one located there facing the right side of truck. Put all these in this bag.
7. Open glove box, remove the 2 phillip screws in the back of glove box and remove the panel. (NOTE: look in hole there, especially the duct work…, remember how it goes!!! The “T” just slides into that opening in the air box/heater core cover!!)
8. Remove your A/C controls (optional.., but makes things easier) BE CAREFUL WHEN REMOVING THE TEMPERATURE CABLE FROM CONTROL ARM!! You can easily break the “L-shaped” tab that holds the cable to the unit. Use cutting pliers/dykes to remove the clip that hold the end of cable from arm here. After removing clip.., use regular pliers to flatten clip so it can be replaced back onto arm during reinstall. Use a 1/4” socket to uninstall the mode selector switch ">" MARK THEM A/C SCREWS and leave vacuum lines attached to it. Undo all wires going to controls. Set this aside.
9. On the drivers side: remove the clip that is going to the trans shift selector that is clipped to column cover.(it is the thing with the string on it…it just pushes right off.)
10. Use a 15mm socket, ratchet, and extension undo the nuts that hold the column up.
11. Pull column down some…, but do not force it all the way down.
12. Look up into hole where column was bolted and check to see if your cluster uses a CABLE type Speedo or not. IF not.., continue on. IF YES, locate the instrument cluster removal section.
13. Top of dash near windshield: Look in the defrost vent holes and remove these 9/32 screws here. “>” MARK them defrost screws-top of dash – there will be 4 of them. (NOTE: Be careful here- swinging a ratchet wildly can result in a broken or cracked windshield!!)
14. The dash is ready for pull-out. Go to passenger side and tug on the bottom of dash while picking it up. It should slide out to you. If not, check over all the above to make sure you got all the screws, bolts, and stuff out of the way. Once done.., break out the strap or cord and strap up passenger side up and high as you can get it. I strapped mine in corner and then pulled bungie over the roof of truck and to driver’s side to keep it taught.
15. Now you can see the access cover to heater core In passenger’s side. There are 6 screws holding this cover on. All ¼” size. “>” MARK THEM H/C ACESS COVER. DO NOT get these screws mixed up with any others.., they are specially made for screwing into plastic ONLY!!
16. Pull on cover towards passenger door and outwards. Do your best not to break this cover. You should now see heater core.
17. Using a ¼” size socket , remove the 4 screws that are holding the heater core straps. One screw at the top of each individual strap and one at the bottom.
18. Pull out on heater core-twisting it out and downward. Make sure if any coolant is left to not spil it in your floor. (use plugs or corks placed in the tubes to keep them from leaking.)
19. Install new heater core. You may have to spread the tubes to get it just right on the outside part. Install screws into the straps.
20. Install heater core access cover. 6 Special short screws.
21. Reverse all the above for dash installation.
NOTE: in some instances, you may have to uninstall the bottom screw that hold the ECM bracket on passenger side and slide ECM down some out of bracket.
NOTE: When REINSTALLING DASH.., makew sure you get the little vent pipe and its "T" in the correct position to go back into whole in heater core cover box or A/C box. Not doing this can result in you having to REDO this dash uninstall !!!! REFER to Step #7 !!!
INSTRUMENT CLUSTER REMOVAL
1. After removing the light panel switch and the A/C controls, you should see inside the holes where they are some 10MM or 7/16 nuts. Remove them now.
2. Gently tug outward on the square plastic dash that covers the cluster to remove it.
3. Now you should see the instrument cluster. There are 4 nuts that are screwed onto the studs sticking out. Remove them now.
Using a screwdriver, GENTLY pry out on the legs of the cluster. USE CAREFUL PRYING HERE!!
You may have to pry up on a lower then, using another screwdriver, you can pry up on the upper one
above it. Once the cluster is free from studs. Reach behind cluster and locate the speedo cable.
Feel for the clip that is holding it there. Push IN towards cluster while PULLING on cable.
It should release. Remove all wire connector blocks from the cluster and set it (the cluster) aside.
4. Reverse the above to install it.
ENjoy the New HEAT ya got now !!