The 1996 Ford Bronco — the last year Ford made this full-size sport utility vehicle — was part of the fifth generation of this popular truck, which was originally introduced in 1966. The heater core in your Bronco may leak from erosion due to a process called electrolysis. If repeated heater core leaks are plaguing your Bronco, consult TSB No. 01-15-6 to resolve the problem.
Things You’ll Need
- Clean rags
- Nut-driver set
- 50-50 blend of water and Ford Premium Cooling System Fluid E2FZ-19549-AA or B, or equivalent meeting specification ESE-M97B44-A
Removal
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Park the Bronco on a sturdy surface such as asphalt or concrete. Open the hood and allow the engine to cool completely.
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While holding a rag over the radiator cap, turn the cap counterclockwise until it hits the first detent and allows the residual pressure to bleed off. Tighten the cap once the pressure is relieved.
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Locate the heater hoses on the passenger side of the engine compartment, and follow them to the heater core hose barbs. Loosen the heater hose clamps, using a nut-driver. Gently twist the hoses to break any adhesion between the hoses and the barbs, then pull the hoses off the barbs. Route the hoses upwards to minimize coolant loss.
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Open the glove compartment. Press and hold the tabs on the upper corners of the glove box sides, then rotate the door open until it locks in the full-down position.
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Locate the heater core cover inside the hole left by the glove box door. Using a nut-driver, remove the seven cover retaining screws. Disconnect the vacuum harness plug near the cover. Leave the harness attached to its looms on the cover. Remove the cover from the heater core housing. Pull the heater core out of the housing. Remove the old seal.
Installation
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Install the new heater core and seal into the heater core housing. Install the cover and retaining screws. Plug in the vacuum harness.
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Rotate the glove compartment door up while holding down on the tabs, until they engage in the dash panel, then close the glove compartment door.
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Push the heater hoses onto the heater core hose barbs. Tighten the clamps securely. Remove the radiator cap and add a 50-percent blend of water and coolant as necessary to bring the level up to full. Install the cap. Add coolant as necessary to the reservoir to bring it up to the "Full" mark.
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Turn the heater controls to the "Full Hot" position with the blower on "High." Start the Bronco and allow it to warm up to operating temperature. Check the system for leaks. Turn the engine off and allow it to cool completely, then top off the coolant in the radiator and reservoir again. Repeat the warm-up cycle as necessary until the coolant level stabilizes at the "Full" mark when the engine is at full operating temperature.
Tips & Warnings
- Do not over-tighten the heater hose clamps. They can distort or break the heater core hose barbs, and cut the hoses as well.
- Ensure that you feel hot air from the vents when warming the engine up. If the temperature gauge is rising and you do not feel hot air, turn the engine off immediately and allow it to cool. Check the coolant levels and try it again.
- Clean up any spilled coolant immediately and dispose of the waste according to local ordinances. Antifreeze is toxic.