Question about 2004 Lincoln Aviator

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The heater core is shot on my 1998 lincoln Navigator. I get no heat. How much should this replacment be.

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  • Lincoln Master
  • 2,989 Answers

The heater core costs about $42.00 at several parts stores....the labor? Well...very good guess is $89.00 per hour to start and depending on what garage you go to...$90 and up.

I could email you the steps to do the job yourself, but I can tell you it is a REAL pain...the entire dash must come off...

Here is a little bit of the steps just to give you and idea:

  1. Disconnect the battery ground cable.
  2. Drain and recycle the engine coolant.
CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the instrument panel. Refer to Section 10.
  2. If equipped with the 5.4L 4V engine, remove the junction block splash shield.
  3. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay.
  4. If equipped with the 5.4L 4V engine, remove the junction block bracket.
  5. Disconnect the heater core hose couplings.
  6. Remove the retaining screw and remove the A/C plenum demister adapter.
  7. Disconnect the vacuum line from the A/C plenum demister adapter.
  8. Remove the heater core bracket.
  9. Remove the 13 plenum chamber top retaining screws.
  10. Remove the plenum chamber top.
  11. Remove the blend door assembly from the case.
  12. Remove the heater core.
    To install:
  13. The installation is the reverse of the removal.
The above is to JUST remove the heater core....this part of how to GET to the heater core:

  • If equipped, remove the floor console assembly.
  • Remove the lower steering column cover bolts and the cover.
  • Remove both front door scuff plates.
  • Remove both side cowl trim panels.
  • Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
  • Remove the radio ground and the GEM/CTM ground bolts.
  • Disconnect the left side instrument panel main wiring harness connector.
  • In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
  • In the driver’s compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
  • Disconnect the air bag diagnostic monitor electrical connector.
  • Disconnect the inertia fuel shutoff switch electrical connector.
  • Remove the right side ground bolts.
  • Disconnect the right side instrument panel wiring harness connectors.
  • Disconnect the electronic blend door actuator electrical connector.
  • Disconnect the climate control head vacuum harness connector.
  • Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
  • At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
  • At the steering column, disconnect the remaining electrical connectors.
  • If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
  • Remove the steering column-to-instrument panel nuts and lower the steering column.
  • Remove the right side front fender splash shield screws and move the shield away from the panel.
  • Disconnect the antenna cable from the antenna base.
  • Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector and/or the sunload sensor connector.
  • Remove the glove box.
  • At the passenger’s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
Place the air bag module in a safe place with the front facing upward.
  • Remove the right side assist handle screw covers, the screws and the handle.
  • At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings.
  • Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
  • Through the air bag module opening, remove the instrument panel bolts.
  • On Expedition, remove the upper instrument panel cowl covers and bolts.
  • On Navigator, remove the instrument panel defroster grille assembly and the instrument panel cowl top bolts.
  • At the relay bracket, remove the instrument panel bolt.
  • At the lower left side of the cigar lighter, remove the instrument panel bolt.
  • At the both sides, remove the instrument panel-to-cowl side nuts.
  • At the steering column opening, remove the instrument panel bolts.
  • Remove the upper instrument panel floor brace bolt.
  • Using an assistant, remove the instrument panel.
  1. If equipped with the 5.4L 4V engine, remove the junction block splash shield.
  2. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay.
  3. If equipped with the 5.4L 4V engine, remove the junction block bracket.
  4. Compress the holding tabs and disconnect the heater hoses from the heater core.
  5. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
  6. Disconnect the vacuum line.
  7. Remove the heater core bracket screws and the bracket.
  8. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
  9. Remove the blend door assembly from the heater housing.
  10. Remove the heater core.

Posted on Dec 01, 2009

  • Greg Bernett
    Greg Bernett Dec 01, 2009

    Just as a ballpark figure....guessing at LEAST $90/hr...$270.00.....and that is a low figure.

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