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Old 09-12-2010, 07:05 AM
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Heater core replacement

Hey guys! 95 wrangler 2.5 no a/c... Core was leaking fluid into the passenger seat, so it needs replaced... Is this an easy fix? What are the steps to replacing it? Thanks in advance y'all are awesome!
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Old 09-12-2010, 09:46 AM   #2
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Not really a hard fix. The biggest thing you could do to make the job easier to to remove the passenger seat to allow yourself to get a better angle to reach under the dash.

There are I believe 6 bolts holding it in behind the fire wall. The hardest one to get to for me was behind the valve cover. You will also be removing part of the lower dash, but that is all bolt on stuff that is not too difficult to reinstall. Good luck with the project.


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Old 09-12-2010, 01:23 PM   #3

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Pull out the battery tray and you will find the hidden nuts. Also, I found out if you pull the radio, you have access to the defroster duct for removal and reinstallation. The entire unit will come out with a bit of persuasion after the firewall nuts and ductwork are removed.

There is a black metal cover with about 15 screws on the firewall side of the heater assembly, and a half dozen rubber grommets on the studs that go through the firewall (don't lose these). Remove the screws and lift off the metal plate and there it is.

The "door" for temp and for defrost/heat mode are a PITA to line back up when reassembling, so an extra set of hands help.

Putting it back in was tricky because you have to line up the core pipes and all the studs to go through the fire wall. I set the bottom of the unit in place and started by guiding the pipes through the holes with a screwdriver, and then just slid the unit left and right, up and down until the studs came through the firewall.

If you get the stud behind the valve cover through, just start the nut back on the stud and it will be easier to blindly get the other stuids through.

Good luck!

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Old 09-19-2010, 06:39 AM   #4
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I know this thread is about the 95 Wrangler but I'm going to add a few comments based on my experience removing the heater core housing to access my blower motor in my 1988 Wrangler. Keep in mind, I'm not sure how many differences there are between the 88 and 95.

1. To reiterate what turdhurdler recommended, removing the passanger seat and battery tray are deffinately worth the effort.
2. After draining the coolant out of the system, and removing the battery tray, I found only four bolts coming through my firewall which attatched the entire heater core and blower motor housing. All four were connected to the firewall with 7/16 nuts. One of them is in plain sight and easy to reach while leaning over the passenger side fender, two of them are below the battery tray and one is behind the valve cover.
3. I removed the two hoses which attach to the heater core nozzles.
4. The blower motor was protruding throught the firewall directly below the battery tray. There was one wire attached to the back of it. Disconnect that wire. Just below the blower motor, I found a rubber hose about 5" long with a 90 degree bend in it. I pulled this off. It's a drain hose for coolant should your heater core sprout a leak.
5. I removed my stereo based on copleydad's recommendations. This did give me very easy access to disconnect the defroster duct from the heater core/blower motor housing.
6. In order to gain a little more wiggle room for the housing assembly to come loose, I had to disconnect the lower part of my dash (the part with the air vents and evaporator core) and lower it to the floor. There were only four screws along the top edge holding it onto the dash.
7. There are two hoses attached to the evaporator core. I did not disconnet these hoses, but I did have to remove the screws which secured the gromet to the firewall which these hoses pass through. This gave me a little bit more wiggle room.
8. I was able to grab hold of the heater core assembly, at this point, and work it loose from the firewall. I wrestled it down to the floor and detached three cables from the assembly which control the flaps inside the ducting. After removing these cables, I was able to pull the assembly out.

Just a note for those with 1988 wranglers who want to upgrade to the Chevy Blazer heater blower motor, it didn't fit in mine. The opening in the firewall was too small for the larger motor which came on the "PM102" blower motor from Autozone. Fortunately, after dismantling my entire jeep to access the blower motor, I found that the only reason my blower motor wasn't working was a little corrosion on the power wire connector (which is easily accessible without having to remove a single nut screw or bolt). So I was able to return the Blazer blower motor for a refund.
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