Rebuilding a factory A/C unit - Done!

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sargentrs
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Re: Rebuilding a factory A/C unit - Updated 12/19

Post by sargentrs »

Spent about 10 minutes trying to saw it off with my hand miter box and thought "I need power!" Clamped my angle grinder with a cutoff wheel in my lightweight vise and made short work of it. Shaved it down to about a 1/4" protrusion on the bottom side. Perfect fit. A dab of gorilla glue and some silicone around the outside and I think I've got something I can work with. Now that I know it works, I'll pick up another one and call that part done.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Other defrost port is glued in and I have a way to connect hoses now. One more issue I ran across that will require a little finesse. The inner damper's pivot rod kinda wobbles around making the door a little loose so it doesn't seal very well. Not sure if there should have been some kind of a bushing there or what but the hole in the case that it goes through is quite a bit larger than the rod. Went wandering around in the parts store looking for something that might work but didn't really find anything suitable. Jacket weather around here and was feeling around in my jacket pockets and found this paint plug, used for masking threaded studs on the paint line at work. Don't remember picking that up but looked like it might fit the bill.
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Last edited by sargentrs on Sat Dec 26, 2015 7:24 am, edited 1 time in total.
Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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sargentrs
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Had to cut it off and shave the OD down with a razor blade but with a dab of gorilla glue to hold it in, it worked nicely. Ready to install the evaporator core, mount the front panel and seal this sucker up at last.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by Mancar1 »

Thanks for posting this, it is very interesting. :thup:
You are doing great.........Keep on Trucking........John
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Thanks, John! Slow going being cold weather here but it's coming along.
Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Well, John, I guess you motivated me. Thought about it for about an hour and then told the wife I was going to the man cave for awhile. I remember there being some gunk around the edges of the case so I guess there should be some kind of gasket. The Armacell worked really well. Sliced off a piece, stuck it to the case and then trimmed off the overlap with a razor blade. Then worked my way around both cases on every flat surface with screw holes in it. After that was done, snapped the two AC registers in place in the front panel. They seated with a satisfying click.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Using 6-32 x 5/8" stainless socket head cap screws and flat nuts, mounted the front panel. Not exactly stunning but pretty clean and a whole lot better than the busted up original. Got both cases with gaskets and the front panel mounted so I taped some paper towels over my front panel so it wouldn't get scratched and mounted the evap core in the rear case. Remember the 3 screws to the left....
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Just goes to show no matter how many photos you take, sometimes you can't figure things out right away. Loose mounted the fan mounting panel in the front panel and test fitted the evap core. That's when I realized I had to mount the fan panel to the rear case and the evap core screws were part of the fan panel mounting. Also discovered that the fan wires are inside all of this and, from looking at my disassembly photos, there must be a hole or something they go through. Process of elimination led me to a slot in the panel and a corresponding slot in the case. Since the fan came pre-wired, I notched both slots allowing the wires to exit the case.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 12/26

Post by sargentrs »

Now with the fan and evap core mounted to the rear case, I screwed it all down snugly. I could flip it over onto the front case and make sure everything fits. It dropped right on with only a minor wiggling. That was enough for me today.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 1/3/2016

Post by Jacksdad »

Yep - I'm watching this one with interest too because my F350 came with a/c (non functioning), but I ditched the compressor and condenser ten years ago thinking it was beyond repair. Thanks for taking the time to detail everything you're doing.
Cold air may yet be in my future :wink:
1971 DRW F350 cab and chassis with an Open Road motorhome conversion, Dana 70, 352 (originally 390)/C6, PS, power front discs, and 159" w/b.
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Re: Rebuilding a factory A/C unit - Updated 1/3/2016

Post by sargentrs »

Thanks, Jacksdad! My truck originally did not have AC and came with a 302/3 spd. I'm swapping in a 351W from an '87 F150 with the serpentine belt configuration. I'll be using all the brackets from that engine to mount a Sanden compressor and aftermarket everything else. I couldn't afford any of the Vintage Air/Old Air Products/Classic Auto Air units and traded my heater only unit for this box so I got it for practically nothing. I lucked out with the evaporator core being good. :D
Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Updated 1/3/2016

Post by Jacksdad »

I'm planning on going with a later model 351W eventually, so that's good to know. I haven't delved deep enough to discover what condition the evaporator's in, but I do need to crawl under the dash at some point and change the heater core at the very least (I bypassed it when the aroma of antifreeze got a little too much). Fingers crossed it's in good shape.
Again, thanks for taking the time to detail the rebuild. Much appreciated :thup:
1971 DRW F350 cab and chassis with an Open Road motorhome conversion, Dana 70, 352 (originally 390)/C6, PS, power front discs, and 159" w/b.
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Re: Rebuilding a factory A/C unit - Done!

Post by sargentrs »

Not too cold today so went down to the man cave to try to finish this little project. Closed up the front/rear cases and put a couple of screws in to hold them together. Installed the temperature switch using U-nuts and sheet metal screws. The probe wire is just supposed to lay in front of the evaporator core but that just didn't seem efficient to me. Went to Ace hardware and picked up some home wiring clamps, pulled the nails out and drilled out the holes for a #6 sheet metal screw. Bend the probe where I wanted it and screwed the clamps in to hold it in place.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Done!

Post by sargentrs »

The went around it and checked everything out. Realized I had forgotten a couple of push washers on the ends of the blend door shafts so tapped those on. Got 'em at Ace Hardware in the specialty hardware section. Finished screwing the cases together and it fit nice and tight. The ArmaCell made a great gasket material.
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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Re: Rebuilding a factory A/C unit - Done!

Post by sargentrs »

Touched up the paint and I'm calling this done. I'll replace the expansion valve before I install it in the truck. Readily available at Old Air Products for about $60. Once the paint dries I'll bag it and place it in the "Done Pile". Another piece to the puzzle is ready to go!
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Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: http://www.fordification.com/forum/view ... 22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1987 F-150 XLT Lariat, 5.0/C6 auto.
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