[GOLDCYLON]

Originally Posted by Dynomite

Daryll........

I just pulled a heater core on a 1990 ZR1 WITHOUT pulling the Dash

There is a little trick on removing one 7mm screws on top of the front vent connection (two 7mm screws). The first 7mm screw is easily removed using a 7mm combination ratchet wrench from underneath. The second top 7mm screw can be reached by taking a long (large) screw driver and pry out on the top duct and against the Heater Core housing top. That gives you just enough room to use a 7mm combination ratchet wrench followed by a needle nose to make the final turns on the 7mm top screw on that vent flange.

So there you have it....a new trick....one guy on Youtube said it was impossible but what does he know

Quickly......as I recall......all accomplished mostly with a 7mm 1/4 inch socket and various 1/4 inch extensions

Outside
1. Drain Coolant.
2. Disconnect Battery (I use a simple quick disconnect).
3. Remove two 7mm screws in Coolant Reservoir in front of Passenger side.
4. Remove two Heater Hoses from Heater Core and set aside the Coolant Reservoir with bottom hose still connected to Coolant System.
I had to cut the Heater Hose between the Coolant Reservoir and Heater Core to remove it.

Inside
1. Remove Passenger Seat (4 nuts and two electrical).
2. Remove hush panel two 7mm screws (and maybe one on right side also).
3. Disconnect light connector on Hush Panel and set Hush Panel aside.
4. Remove three 7mm screws at bottom of Heater Core Housing accessing from under right side Hush Panel area.
5. Remove one 7mm screw on right side of Heater Core Housing (half way down) accessing from under right side Hush Panel area.
6. Remove several 7mm screws back side of glove box.
7. Remove phillips screw front latch glove box and remove glove box.
8. Remove one top 7mm screw on left side that can be seen on Heater Core Housing from glove box area.
9. Remove one 7mm screw top right side Heater Core Housing that cannot be seen directly but use a mirror.
10. Remove bottom 7mm screw from Heater Core Housing holding air duct flange (there is a bottom and top screw).
Use a 7mm combination ratchet wrench.
11. Pry open a great space between Heater Core Housing and top duct with large screw driver.
12. Remove top 7mm screw from Heater Core Housing holding air duct flange.
I actually used a needle nose pliers to rotate the screw and lift out after it was loose using a 7mm combination ratchet wrench.
13. Now........wiggle out the Heater Core Housing down and out.
14. Remove bottom Heater Core holder screw and open Heater Core Holder.
16. Remove Heater Core.

Replacement of Heater Core Housing will involve a magnetic 7mm 1/4 inch socket to insert the various 7mm screws

Actually pretty easy with the trick of step 11 to remove the 7mm screw in step 12.

Well I have to say Cliff that the General did not plan on the Amercian Farmer approach to out engineering a solution. Maybe your new forum handle should be "Scotty" he can damn near fix anything. Most folks dont know that an old tractor can be fixed with a screwdriver a pair of pliers and bailing wire.

Pretty slick and well done. Still a hell of a lot of work. Please tell me you HAD to replace your heater core on one of your rides and this was not simply done for two reasons.

1. You were bored after making a prototye tool and mowing down a bunch of soybeans and said, Sleep who needs sleep?

2. You simply love a challenge.