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FORD BRONCO
-> CLIMATE CONTROL; heater, AC, blower motor/resistor
-> Air Conditioning
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WELCOME to MIESK5's BIG BRONCO LINKS - We now have over 26,000 LINKs!
This is a Ford Bronco, Truck & Van Technical & Parts LINKS site developed by the MIESK5 Family & is not affiliated with the Ford Motor Co. in any manner.
Although we initially developed this site for 78-96 Big Broncos, information in many Links also applies to F, E Series & Cars. UPDATE; all Links via web.archive may be down; Copy orig. URL & go to http://replay.waybackmachine.org/ to search for the new archived copy
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Accumulator/Drier
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Air Conditioning Parts Catalog, Ford
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Black Death, Ford
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Compressor
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Condenser
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Evaporator
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Filtering Refrigerant, System Flushing, Tracer Dye, Leak Testing, O Ring Tool TSB Listing for Service to Include Latest Model Years TSB 96-15-6
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Flushing Procedures Service Tip TSB 95-18-4 for 85-95 Bronco, Econoline, F-150-350 Series; 85-90 Bronco II; 85-96 Ranger; 86-95 Aerostar; 91-96 Explorer; 93-95 Villager; 95-96 Windstar, etc.
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Hoses
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Identification Of Non-Ford Approved Refrigerants TSB 99-19-6 for 85-96 Bronco, 85-90 Bronco II, 85-97 F-250 HD, F-350, 85-2000 Econoline, F-150, F-250 LD, Ranger; 86-97 Aerostar, 88-97 F Super Duty, 91-2000 Explorer, 95-2000 Windstar, etc.
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Installation
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Insufficient Refrigerant Oil TSB 97-10-5 for 93-96
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Low or No Heat/Air Conditioning, High Effort to Turn Temperature Control Knob, Poor Temperature Modulation TSB 96-13-7 for 92-95 Bronco, F Series, F-47
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O-Ring
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O-Ring Removal from Spring Lock Coupler Service Tip TSB 95-2-2 for 82-95 Bronco, F Super Duty, F-150-350 Series, Ranger; 83-90 Bronco II, 86-95 Aerostar, 88-95 Econoline, 91-95 Explorer, 95 Windstar, etc.
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Odors, Eliminate Air Conditioning Musty & Mildew Type TSB 98-2-7 for 92-98
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Orifice Tube
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Pressure Relief Leak TSB 91-20-12 for 88-91 Bronco & F Series
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R-134a & R-12 Recharging, Conversion & TSBs
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Refrigerant Substitution TSB 96-17-10 for 80-93 Bronco, F Series & many others
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Refrigerator Type Smell or Chemical Type Odors TSB 91-15-05 for 80-91 Bronco, F Series & many others
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Spring Lock Coupling w/ Three (3) O-Rings & R-134a Fluorescent Tracer Dye TSB 97-3-5 for 96 Bronco, 96-97 Aerostar, Econoline, Explorer, F-150-350 Series, Ranger, Windstar; 97 Expedition, Mountaineer & Tool
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Whistle Noise in Air Conditioning System TSB 95-06-15 for 95
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Wiring Diagram
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System Function & Diagram; "... The compressor (4) pulls low-temp./press. refrigerant vapor (11) from the accumulator (3) and raises its pressure & temperature. As it flows through the condenser ( 8 ), the refrigerant's higher-than-ambient temperature causes heat to flow out into the airstream, allowing the refrigerant to condense into a high-temp./press. liquid (14). The pressure is a result of the precise restriction caused by the orifice tube (9). As the refrigerant flows slowly through it, the pressure drops suddenly, causing the refrigerant to flash-boil from a low-press. liquid (13) into a low-temp./press. vapor (11). To change from liquid to vaport, the refrigerant must absorb heat through the evaporator, which cools the cabin airstream. The refrigerant then returns to the accumulator where it continues to boil & is dried by a dessicant. If refrigerant leaks out OR the cabin airstream is too cold, the pressure in the evaporator will be too low to keep the cycling switch (2) ON below ~20psi. If the system is overcharged OR the ambient airstream is too hot, pressure in the condenser will cause the pressure cut-off switch (6) to turn OFF above ~400psi. If that fails, then the pressure relief valve (5) will vent refrigerant above ~500psi..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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"...The air handling system is designed to provide defrost when no vacuum is applied to any of the three air door vacuum motors. This is done to prevent a situation where defrost cannot be obtained due to a system vacuum leak. Instead, a leak in the vacuum control circuit will send all airflow to the defroster outlets. This condition may occur during acceleration (slow leak), may exist at all times (large leak) and may happen only when certain specific functions are selected, indicating a leak in that portion of the circuit. ..." from F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual
Source: by Ford via thedieselstop.com
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A/C Switches to Defrost in MAX Mode in 92-96; "...On the newer broncos, there are colored plastic lines that go to that vacumn actuator (Miesk5 Note, it is the Vacuum Control Valve). They could be white also. they get very brittle when they get old. they will be hard plastic lines that go to the vacuum canister and possibly away from it. I had to replace those lines with rubber hose when it did the same thing. Just look for some exposed white or colored plastic looking tubes. If you fiddle with them, they will most likely break apart, then you can follow the line and replace it with rubber. You can't get those lines replaced with original, for obvious reasons..."
Source: by petlover07 at FSB
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A/C Switches to Defrost in MAX Mode in 92-96; "...Well you can physically move the lever to see if the actuator (Miesk5 Note, it is the Vacuum Control Valve) is locked up for starters. And then you can start the truck (to get a vacuum source), and run a new line from a known vacuum source to the actuator (Miesk5 Note, it is the Vacuum Control Valve)."
Source: by Dan50 at FSB
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A/C Switches to Defrost in MAX Mode Vacuum Line Repair in a 92; "...began pulling out the tubing. To my surprise, the tubing that inside the plastic tubing was like new..." read more
Source: by JohnMcD348 at FSB
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A/C Switches to Defrost in MAX Mode; "...If MAX A/C only blows out the defrost registers, or if it switches to defrost during hard acceleration, this vacuum line (to the recirculate motor) is the reason. The white plastic is far more susceptible to UV light than any other color, and the gap along the edge of the hood allows it to degrade..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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A/C Switches to Defrost in MAX Mode; "...noticed was the white tube that connects the AC was missing. I searched around and found it was disconnected. I cut the line and reaatached it and the AC works great..."
Source: by seth15c at FSB
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Air Conditioning & Heater Vacuum Diagram in a 95
Source: by Chilton
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Chilton Manual for 66 - 81 Bronco, Scanned Copy
Source: by Chilton via broncocity.com
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Climate Control System Wiring Diagrams in a 96; Heater, A/C & Heater Blower Motor Connector, Blower Motor Switch Resistor Connector, A/C-Heater Control Assembly Connector, A/C Cycling Switch Connector, A/C Pressure Cut-Off Switch Connector Pin-Out Diagrams from 1996 F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual
Source: by Ford via thedieselstop.com
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Clutch Connector Location in Engine Bay Diagram in an 87-88 4.9L; #1
Source: by Ford via Chilton
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Clutch Cycling Switch (ACCS) Overview; see page 34 in Ford EEC IV Operation & Testing Overview; PowerPoint Presentation
Source: by Ryan M (Fireguy50) at powershow.com
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Component pics in 80-96; "...Separate suction & discharge hoses were used until ~'92. Mid-years (~'86-90) used square-drive shutoff valves at the compressor ports. Early models ('80~84) used an autmatic shutoff valve & filter in the connection between the condenser & the condenser-to-evaporator hose. The low pressure switch screws onto an automatic valve on the accumulator. R-134a models have a hi-press. cutout switch on the discharge hose..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Control Assembly Connector Location, Behind Instrument Panel Diagram in a 96, Page 2
Source: by Ford via Chilton
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Control Assembly Illumination Connector Location Behind Dash in a 90
Source: by Seattle FSB (SeattleFSB) at SuperMotors.net
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Control Diagram in a 78
Source: by Indybronco (Lula Mae) at SuperMotors.net
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Control Overview in 80-86; "Off- Vacuum is applied to da Outside Recirc Door Vac Motor, closing that door to outside Air. Normal A/C - Outside-Recirc Door is open to outside air. The panel door directs air to the instr panel registers. The Temperature Control Lever moves a cable connected to da Temp Blend Door that mixes heated & un-heated air In Defrost Mode; with No vacuum to any vacuum "motor" (cannisters looking thangs), air Flows to Defroster outlets (& air compr clutch is engergized) Vent - Outside-Recirc Door is open to outside air, as in Normal A/C. Vacuum is applied to the Panel Door Vacuum Motor, letting air flow only to the instr panel registers. In the same way, the defroster outlets are closed by the Floor/Defrost Vacuum Motor. Floor - The Outside-Recirc Door is Open to outside air. With No Vacuum at the Panel Door Vacuum Motor. The Panel Door directs air to the floor outlets. Mix - Vacuum is applied only to Port A of the Floor/Defrost Vacuum Motor positioning the Floor/Defrost Door at mid-position. Air Flow is split between the floor & windshield. There is no vac at the Panel Door Vacuum"
Source: by miesk5 at FSB
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Control Panel & Ventilation Duct pic for 87-early 88 Bronco & F Series (with 4 slide knobs & central A/C button)
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Control Panel Diagrams & Overview in 92-96; "...In the OFF position, all doors are in the vacuum-applied position with the exception of the PANEL door. The blower & compressor clutch circuits are not energized. In the MAX A/C position, all vacuum operated doors are in the vacuum position. A/C damper inlet door (19C802) air is shut off and the passenger compartment air is recirculated to maximize cooling. Discharge is through panel register. A/C clutch & blower circuits are energized. In the NORM A/C position, outside air is allowed to enter the passenger compartment. The air passes through the A/C evaporator core (19860) and is cooled before reaching the passenger compartment. Discharge is through panel register. A/C clutch & blower circuits are energized. Ventilation is delivered through the instrument panel registers when the function selector knob in the A/C control (19980) is set in the VENT position. In the VENT position, no vacuum is applied to the OUTSIDE/RECIRC. vacuum control motor (18A318 ) and the door is open to the outside. The air coming in through the cowl is discharged through the panel registers. The blower circuit is energized, but the A/C clutch is not. In the FLOOR position, no vacuum is applied to the vacuum control motor and the OUTSIDE/RECIRC. door is open to the outside. Air is discharged through the heater outlet floor ducts (18C433) with a small amount going to the windshield defroster hose nozzles (18490). The blower circuit is energized, but the A/C clutch is not. In the MIX position, outside air is discharged through the windshield defroster hose nozzles and the heater outlet floor ducts. A/C clutch & blower circuits are energized. In the DEFROST position, outside air is discharged through the windshield defroster hose nozzles with a small amount going to the heater outlet floor ducts. All doors are in the no vacuum position. A/C clutch is engaged in ambient temperatures above approximately 10�C (50�F) & the blower circuit is energized. The PANEL/FLOOR, FLOOR/DEFROST and OUTSIDE/RECIRC doors are vacuum operated. For maximum cooling, the temperature knob should be set in its fully counterclockwise position; the function knob should be in the MAX A/C position; and the blower motor (18527) should be set for a desired rate of airflow. Even though the function knob is on MAX A/C, the temperature knob, being manually controlled, may be set to modify the temperature of the air and the path through which the air flows. Another characteristic of the MAX A/C setting is the increased noise level of the blower motor. Speed does not change when the OUTSIDE/RECIRC. door is moved to either of its two positions. The difference in noise level is that an open recirculation door exposes the passenger compartment directly to the noise. When insulated against the noise with the recirculation passageway closed, the speed appears to be less. The control knob operates an A/C switch that is attached to the backside of the A/C control by one screw and retainer tabs. Five hoses (black, white, red, blue, yellow) extend from the A/C control just below the electrical connector for the mode selector switch to the vacuum control motors and vacuum supply. The solid black hose goes to the vacuum supply through a tee-shaped A/C vacuum check valve (19A563), which attaches the A/C vacuum reservoir tank and bracket (19A566) and engine source. The white hose actuates the OUTSIDE/RECIRC. air door two-position vacuum control motor. The blue hose actuates the FLOOR/PANEL air door two-position vacuum control motor. The red and yellow hoses actuate the FLOOR/DEFROST three-position air vacuum control motor. Each end of each hose slides onto the nipple of the vacuum port to which it attaches..." SEE DIAGRAM
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Control Panel Overview in an 83 from Owner's Manual
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Control Panel Overview in an 86 from Owner's Manual
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Dash Harness pic in a 96 F 150; "...some connectors have been removed..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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E4OD Controls Overview, Sensors, DTC (s) & Diagram; "... Air Conditioning (A/C) Clutch 2884: The air conditioning clutch is an electromagnetic clutch that is energized when the clutch cycling A/C pressure cut-off switch closes. The A/C pressure cut-off switch is located on the suction accumulator-drier. The closing of the A/C pressure cut-off switch completes the circuit to the clutch and draws it into engagement with the compressor driveshaft. Used as an input to determine electronic pressure control when the air conditioning clutch is engaged to compensate for the additional load on the engine. Failed on — electronic pressure control slightly low with A/C off. Failed off — electronic pressure control slightly high with A/C on. DTC 539, P1460, P1463, P1464..." READ MUCH MORE
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Electrical and Vacuum Troubleshooting Manual (EVTM) for an 86 (Partial); Speed Control on pages 135-139, A/C & Heater on pages 140-145, Radio on pages 127-129
Source: by Ford via Chris B (Blue, bronco boy) at telus.net
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Engine Conversion Kits for Bronco & Ford Trucks (sales catalog w/pics & descriptions)
Source: by L&L landlproducts.com
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Filtering in a 96 from F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual
Source: by Ford via thedieselstop.com
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Floor Panel Door, Temperature Blend Door (Cable Controlled), Floor & Defrost Door, etc. Diagrams in a 96 from Workshop Manual
Source: by Ford via miesk5 at Ford Bronco Zone Forums
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Flushing Procedures Service Tip TSB 95-18-4 for 85-95 Bronco, Econoline, F-150-350 Series; 85-90 Bronco II; 85-96 Ranger; 86-95 Aerostar; 91-96 Explorer; 93-95 Villager; 95-96 Windstar, etc.
Source: by Ford via performanceprobe.com
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Flushing Procedures Service Tip TSB 95-18-4 for 85-95 Bronco, Econoline, F-150-350 Series; 85-90 Bronco II; 85-96 Ranger; 86-95 Aerostar; 91-96 Explorer; 93-95 Villager; 95-96 Windstar, etc.
Source: by Ford via Chilton
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Forums, Automotive
Source: by aircoparts.com
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High Idle & Dieseling Troubleshooting Chart in a 94, from PCED Chart 7 for a 94; Preliminary Checks; Vacuum Leaks, Throttle Plate & Linkage, Speed Control Chain Binding/Sticking, Air Intake Tube/ Intake Manifold Leaks; AC System; Clutch, Demand & Cyclic Pressure Switches, Refrigerant charge, etc.)..." READ MORE
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Leak Detection with UV/blue light, General (mostly ad, but good DIY info tips)
Source: by tracerline.com
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Low Pressure Switch Location; "...switch is located on the accumulator. This is also called the receiver/dryer. It is a cylinder, black or aluminum, mounted just ahead of the evaporator/blower assembly. The switch is threaded onto a port on the side of the accumulator. Here is a tiny photo of the general area you will be looking at; There should be a two wire plug attached to the switch. Unplug the connector, use a jumper wire to short the two pins together. Start the truck, turn on the A/C, verify if the clutch engages. If it does, then it a bad switch or extremely low charge of refrigerant that is causing your problem. The low pressure/clutch cycling switch is closed between ~24 and 45 PSI.If it does not work then it is another electrical problem further upstream. Your A/C should also have a high pressure switch. It should be attached to the line between the compressor and condenser, that would also prevent the clutch from engaging. The high pressure switch is supposed to open at ~400PSI..."
Source: by rla2005 (Randy) at FSB
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Mini-Tube Vacuum Hose Damage Repair in a 92
Source: by JohnMcD348 at FSB
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Mini-Tube Vacuum Hose Service in Climate Control System in a 96; "...Measure the length of the damaged area of the mini-tube vacuum hose. Cut a piece of standard 3mm (1/8-inch) ID vacuum hose approximately 25mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. Cut the mini-tube vacuum hose on each side of the damaged area and remove damaged portion of the mini-tube vacuum hose. Dip the mini-tube hose ends in Tetra Hydro Furan (THF) or Methyl Ethyl Ketone (MEK). Either of these solvents will act as a sealer for the repair of the mini-tube vacuum hose. Insert the ends of the mini-tube vacuum hose approximately 9mm (3/8 inch) into the ends of the standard 3 mm (1/8-inch) ID replacement vacuum hose. Shake the service joint after assembly to make sure solvent is dispersed and vacuum line is not blocked internally. Test system for a vacuum leak in area serviced..." from 1996 F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual
Source: by Ford via thedieselstop.com
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Motorcraft Chemicals & Lubricants 2010 Catalog; 7.81 MB pdf
Source: by Ford
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Overview in a 96 from 1996 F-150, 250, 350 (4x4), and Bronco Vehicles Workshop Manual
Source: by Ford via thedieselstop.com
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R-12 To R-134a Retrofit Kit Availability, Vehicles With Factory Installed A/C Only TSB 98-4-8 for 88-93 Bronco, Econoline, F Super Duty, F-150-350 Series, Ranger; 86-93 Aerostar, 88-90 Bronco II; 91-93 Explorer, 93 Villager; 85-95 F Series, etc.
Source: by Ford via performanceprobe.com
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Registers Location in Parts Break-Out Diagram in 92-96 w/ Nomenclature
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Removal; "...The entire A/C refrigerant system can be removed as a unit from all '80-96 gasoline (& probably diesel) F-series & Broncos without much trouble. The fan & shroud have to come out so the radiator can tilt back, and the belt has to come off, of course. But no coolant, refrigerant, or other fluid lines have to be opened..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Repair Price Estimator, Bronco from 90-96 and other Fords; including labor & parts, shops in area, by Zip Code
Source: by RepairPal
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Symbols in Wiring Diagrams
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Tech Tip Guide, General
Source: by spectrapremium.com
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Temperature Door Location in Parts Break-Out Diagram in 80-86
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Testing Wiring with a Multi Meter, General; Opens, Short, Voltage & Voltage Drop, Continuity & Diodes
Source: by freeautomechanic.com
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Troubleshooting, general
Source: by freeautomechanic.com
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Vacuum Circuit, Floor Panel Door, Temperature Blend Door (Cable Controlled), Floor & Defrost Door etc. Diagrams in a 96 from Workshop Manual
Source: by Ford via thedieselstop.com
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Vacuum Control Valve Depiction in 92-96
Source: by miesk5 at FSB
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Vacuum Control Valve Location in Parts Break-Out Diagram in 92-96
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vacuum Diagram in 92-96; "...'80-91 similar, except '87-early '88 w/factory air..."
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vacuum Diagram, AC & Heater for 93
Source: by Bronco Rob (BroncoRob) at FSB
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Vacuum Hose Harness Pic in 80-96; "...80-96 similar, except 87-early 88 w/factory air; The 80-86 vacuum tank is a plastic ball on the R wheelwell..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vacuum Leak Test; On an idling engine check for vacuum leaks using a mechanic's stethoscope with the probe removed, or a ~3' garden hose section. Don't spray flammables on a running engine. MIESK5 NOTE; Also check: vacuum hoses; intake manifold gasket & throttle body; PCV line; vacuum reservoirs: EGR Sys Vacuum Tank & 2ndry air (coffee can); AC, heater, defroster, vent control ckt & vacuum tank (plastic ball type), under dash & lines to heat/blend/etc. doors; power brake booster; cruise control ckt, etc.... where applicable; (combined w/ Steve83's info, thnx) BEWARE OF BELTS/PULLEYS, FAN AND HOT ENGINE
Source: by miesk5 & Steve83 at Ford Bronco Zone Forums
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Vacuum Line (Hose), Mini-Tube Damage Repair in a 92
Source: by JohnMcD348 at FSB
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Vacuum Line/Hose;"...The vacuum hoses used in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel. Because of the materials used, the vacuum hoses should never be pinched off during diagnosis to locate a leak. Use Rotunda Vacuum Tester 014-R1054 or equivalent to locate vacuum leaks. A wood golf tee can be used as a plug when it is necessary to plug one end of a vacuum hose for leak test purposes..." from F-150, F-250, F-350, F-Super Duty and Bronco, F-Super Duty Motorhome Chassis Workshop Manual
Source: by Ford via thedieselstop.com
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Vacuum Motor Locations in Parts Break-Out Diagram in 80-86
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Wire Color Code Abbreviation Chart; see post #4; BK Black, BL Blue, BR Brown, DB Dark Blue, DG Dark Green, GN Green, GY Grey, LB Light Blue, LG Light Green, N Natural, O Orange, P Purple, PK Pink, R Red, T Tan, V Violet, W White, Y Yellow
Source: by miesk5 at FSB
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Wiring & Vacuum Diagrams in a 94
Source: by Richard B at SuperMotors.net
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Wiring Diagram in an 84 (diagram #3)
Source: by toddcomputer.com
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