Ford Retrofit Procedures

Please send comment, corrections and additions to: PParish@delanet.com

Bottom of Page

Ford Retrofit Kit Information
From: Technical Service Bulletin No: 96-15-7
Ford has designed and tested specific retrofit kits for their vehicles. They are the most comprehensive kits available from any vehicle manufacturer
Refer to Fords Technical Service Bulletin No: 96-15-7 for more information on their recommendations.
Table of Parts as in TSB 96-15-7
Recommendations From A/C Shops and Aftermarket:
On systems that control the evaporator pressure to control the evaporator temperature, lower the minimum pressure with R-134a. This is because the pressure temperature relationship of R-12 and R-134a is different. For instance at 25 F the pressure of R-12 is 24.6 PSI and the pressure of R-134a is 22.1 PSI.
Pressure Temperature Table
When the condenser is replaced because it is leaking, make sure you install a multiflow model.
My Recommendations
My recommendations are in line with aftermarket recommendations. Aftermarket recommendations are those of companies such as Everco, Four Seasons and Murray.
MINERAL OIL REMOVAL
Ford states that PAG oil, mineral oil and R134a refrigerant can be mixed together in a A/C system without causing a problem. The removal of mineral oil during retrofit is not required unless noted under flushing procedures of TSB 96-15-7. I recommend that you remove as much oil as possible! The aftermarket agrees and states that too much oil will decrease performance.
FLUSHING THE SYSTEM
Ford recommends flushing only on a few models. Ford provides instructions for flushing with their retrofits kits. Ford endorses Terpene based flush solvent with a closed flush. See TSB 96-15-7. I recommend flushing of the air conditioning system when possible, see general retrofit procedures. Flushing also remove debris and contaminants. I always flush when I change a compressor or when there is signs of contaminants.
O-RINGS & GASKETS
All o-rings and gaskets replaced should be R134a compatible. I cover o-rings and gaskets with mineral oil.
HOSE REPLACEMENT
Some Ford retrofit kits contain a discharge hose while others contain a suction hose assembly. It seems that Ford changes hoses according to failure history. Ford states that you should of course replace any hoses that show signs of leaking.
COMPRESSOR
The compressor is not part of the normal retrofit. When you do change a compressor make sure you know what type oil it contains.
CONDENSER AND AIR FLOW (HEAT EXCHANGE)
Heat exchange and air flow improvement varies according to the vehicle, but it is obvious that Ford sees the need to improve in this area. Ford replaces the condenser and adds air deflectors on most of their larger vehicles to improve heat exchange. The air deflectors are added around the condenser to improve the air flow through it. All full sized pickups and vans get a condenser, cooling fan clutch, and air deflectors along with their basic components. Ford changes the cooling fan motor on some models to an improved version. Ford changes the electric cooling fan module to alleviate problems.
FILTER DRIER / ACCUMULATOR REPLACEMENT
Ford state that change is not recommended, but this may be to keep them from spending money when the retrofit is done under warranty. I recommend changing the drier. DT>EXPANSION VALVE
The expansion valve is not part of the normal retrofit. Some shops I have talked to install new expansion valves when they retrofit a dual evaporator systems.
EVAPORATOR
The evaporator is not part of the normal retrofit.
SUCTION VALVES
Suction Throttling Valves (STV) control and cycle the minimum pressure in the evaporator, there by controlling the minimum temperature. The aftermarket thinks they should be adjusted back 3 to 4 PSI with R-134a in order to achieve the same temperature. Most valves will have a lock nut and an adjustment screw on the inlet end. One eight turn counterclockwise lowers the low side pressure approximately 2 PSI and one quarter lowers the low side pressure approximately 4 PSI.
CLUTCH CYCLING SWITCH
Ford recommends replacement of the clutch cycling pressure switch (CPS) and includes one in their retrofit kits.
Recommendations From A/C Shops and Aftermarket:
Lower the adjustment of the clutch cycling switch to 21 to 22 PSI. This is because the pressure temperature relationship of R-12 and R-134a is different. For instance at 25 F the pressure of R-12 is 24.6 PSI and the pressure of R-134a is 22.1 PSI.
Pressure Temperature Table
If it is adjustable there will be an adjustment screw between the two terminals. One eight turn counterclockwise lowers the cut out pressure approximately 2 PSI and one quarter lowers the cut out pressure approximately 4 PSI.
HIGH PRESSURE RELIEF VALVE (HPRV)
None: See refrigerant containment switch below.
HIGH PRESSURE CUTOUT (HPCO) SWITCH
On some models Ford adds a HPCO switch. We think a high pressure cut out switch is a worth while safeguard.
OTHER PARTS
Ford includes a refrigerant containment switch (RCS) in their retrofit kits.
OIL REPLACEMENT
Ford recommends you refill the system with a full charge of the proper PAG oil. We recommend that you use Ester oil if you flush.
SERVICE PORT ADAPTERS
Special R134a only service ports that meet SAE requirements are required by law.
REFRIGERANT REPLACEMENT FOR R12
Ford recommends R134a as the only substitute for R12 refrigerant. Recharge the system with about 15% less R134a than the R12 specification.
LABELS
Special R134a service labels that meet SAE requirements are required by law.

| Return to E38.org | Retrofit Index Page|


TOP Of Page