Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1986 Ford Aerostar V6-183 3.0LFACTORY OEM SERVICE PROCEDURE
Expansion Block/Orifice Tube: Service and Repair
NOTE: This Procedure Applies to Front and Rear Expansion Tubes
Removal
1. Discharge refrigerant from system.
2. Disconnect and cap liquid line from evaporator core inlet tube.
3. Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet tube.
4. Using tool T83L-19990-A or equivalent, engage with the two tangs on the orifice tube.
CAUTION: Do not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off.
5. Hold T-handle of removal tool to prevent it from turning, and run nut down against evaporator core tube until orifice tube is pulled from inlet tube.
6. If the A/C Evaporator Core Orifice breaks in tube, it must be removed from the tube with Broken Orifice Tube Extractor T83L-19990-B.
7. To remove a broken Orifice Tube, insert the screw end of the Extractor Tool into the tube and thread the screw end of the tool into the brass tube in the center of the orifice body. Then pull the orifice from the tube.
8. If only the brass tube is removed in step 7, insert the screw end of the extractor tool into the orifice body. Then pull the body from the tube.
Installation
1. Lubricate the O-rings on the A/C Evaporator core orifice liberally with clean refrigerant oil.
2. Place the orifice in the remover/replacer tool and insert into the evaporator tube until the orifice is seated at the top.
3. Remove the tool from the orifice.
4. After checking the condenser to evaporator tube coupling end for a missing or damaged spring, install two new O-rings lubricated with clean refrigerant oil onto the male fitting. Insert the male fitting into the inlet tube until the spring lock coupling is fully engaged.
5. Leak test, evacuate and charge system.
6. Check system for proper operation.
Fig. 2 Spring lock coupling disconnect & connect:
Removal
1. Discharge refrigerant from system.
2. Disconnect and cap liquid line from evaporator core inlet tube.
3. Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet tube.
Fig. 5 Fixed orifice tube:
4. Using tool T83L-19990-A or equivalent, engage with the two tangs on the orifice tube.
CAUTION: Do not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off.
5. Hold T-handle of removal tool to prevent it from turning, and run nut down against evaporator core tube until orifice tube is pulled from inlet tube.
6. If the A/C Evaporator Core Orifice breaks in tube, it must be removed from the tube with Broken Orifice Tube Extractor T83L-19990-B.
7. To remove a broken Orifice Tube, insert the screw end of the Extractor Tool into the tube and thread the screw end of the tool into the brass tube in the center of the orifice body. Then pull the orifice from the tube.
8. If only the brass tube is removed in step 7, insert the screw end of the extractor tool into the orifice body. Then pull the body from the tube.
Installation
1. Lubricate the O-rings on the A/C Evaporator core orifice liberally with clean refrigerant oil.
2. Place the orifice in the remover/replacer tool and insert into the evaporator tube until the orifice is seated at the top.
3. Remove the tool from the orifice.
4. After checking the condenser to evaporator tube coupling end for a missing or damaged spring, install two new O-rings lubricated with clean refrigerant oil onto the male fitting. Insert the male fitting into the inlet tube until the spring lock coupling is fully engaged.
5. Leak test, evacuate and charge system.
6. Check system for proper operation.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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