Classic Auto Air has been serving '65-'73 Mustang enthusiasts with new and remanufactured climate control systems and parts for more than 30 years. When Al Sedita founded the company 38 years ago to serve Rolls Royce owners in the hot Florida climate, his goal was to provide the best possible systems and parts in the marketplace. Soon, there was another demand -- classic '65-'73 Mustangs. Today, Classic Auto Air remains committed to early Mustangs, and now they've added another generation - the '87-'93 Fox-body Mustangs.
We've been instrumental in helping CAA prototype their new and remanufactured climate control systems and parts for '87-'93 Mustangs by shipping them a complete system from an '89 Mustang GT. Thanks to the efforts of CAA's vice-president and general manager Tim Cordileone, along with the company's product development staff, our 23 year-old air box was restored to like-new condition and returned for installation along with everything needed to update the out-dated R-12 system to R-134a. The key to living with R-134a has been learning how to develop new systems and components designed to operate efficiently with it. This is where CAA has done its homework with easy conversion packages you can install in your home garage and have serviced by a licensed technician.
Fox-body Mustang climate control systems operate just like their ancestors. Switch operation vectors intake manifold vacuum to three air door servos to place the air where we want it. The fan switch not only controls fan speed but also air conditioning compressor clutch operation. Fan speed is controlled via a three-element resistor, just like the classics. We get compressor clutch function in air conditioning mode as well as defrost. The three-dial electro-pneumatic climate control operates the same way as classic '67-'78 Mustangs.
1 Classic Auto Air's remanufactured...
1 Classic Auto Air's remanufactured climate control system for '87-'93 Mustangs is a completely remanufactured air handler assembly with new evaporator, heavy-duty aluminum heater core, new blower motor and foam, reconditioned or new vacuum servos and hoses, and new electrics. CAA will want your old core. If you are concerned with getting your core back, let CAA know when it is shipped and include the blower motor plug for installation on the new motor. This is the same basic unit found on '79-'86 Mustangs as well.
2 The '79-'93 Mustang climate...
2 The '79-'93 Mustang climate control systems operate the same way our classics do with vacuum servos to move air doors to whatever position you desire. There are three servos.
3 System removal is quite...
3 System removal is quite involved and mandates patience. Because these climate control systems were installed before the dashboard and steering column went in, the dashboard has to be removed and steering column dropped. Take pictures as you go to help document how it goes back together.
Many Fox-body Mustangs still have their R-12 refrigeration systems. R-12
was federally phased out in the 1990s, replaced by mandatory R-134a. This
phase-out puts many of us in the unfortunate position of having to convert to
an R-134a system because R-12 is no longer legally available. R-12 is also very
expensive if you can fnd it. It's also complex to convert to an R-134a system
because hoses, orifce tubes, system fushes, and other components have to
be changed.
Classic Auto Air takes the guess work out of converting Fox-body Mustangs to R-134a
with the '87-'93 Mustang R-134a Upgrade Kit. This is something you can do in your
home garage over a weekend, then have the system properly evacuated and serviced
by a licensed professional on Monday. CAA's simple kit includes a high-effciency parallel
fow direct-ft condenser, a Sanden rotary compressor, a receiver tank, a pressure
switch, brackets and hardware, R-134a specifc hoses and o-rings, and a six-rib serpentine
belt. This Sanden compressor is engineered for 6,000 rpm continuous duty.
4 Console removal is first...
4 Console removal is first because it is tied to the dashboard and parking brake assembly. Once the wiring is disconnected, removal is straightforward. Note that there are many screws and attachment points.
5 The steering column collar...
5 The steering column collar is next using a 1/4-inch drive 8mm socket or Phillips head.
6 Instrument panel switches...
6 Instrument panel switches are snapped into place. All you have to do is pop them out and disconnect the wiring. Because multiplex plugs are switch specific, you cannot get them mixed up. The cluster bezel is retained with 8mm or Phillips head screws. Once the bezel is removed, cluster access is easy.
7 The dashboard is retained...
7 The dashboard is retained with sheet metal screws, which call for 8mm socket or Phillips head screwdriver.
8 The steering column is...
8 The steering column is retained with two bolts/studs and a U-clamp. Once the steering column drops, the dashboard is free.
9 The dashboard is removed...
9 The dashboard is removed by feeding plugs through the back and disconnecting the main wiring loom. By the way, Ford doesn't call this the "dashboard." It's known as the "IP," or "instrument panel."
10 The receiver tank (accumulator)...
10 The receiver tank (accumulator) and related plumbing are disconnected and removed next.
11 Quick connect lines are...
11 Quick connect lines are disconnected using color-coded quick disconnect tools available from just about any auto parts store. Color indicates line size.
12 The air box to firewall...
12 The air box to firewall retaining nuts are removed next using a deep-well 13mm socket.
13 Gil Roiz of Mustangs Etc....
13 Gil Roiz of Mustangs Etc. removes our climate control system and carefully packages it up for shipment to Classic Auto Air. As a matter of policy, CAA photographs your components when they arrive for customer confidence.
14 You're probably going...
14 You're probably going to need two of these spacers to mount your Classic Auto Air climate control package. This part, #1L2Z-19C856-AA, is still available from Ford or from Mustangs Etc.
15 This is the evaporator...
15 This is the evaporator drain seal, which is positioned in the firewall. It's available only as used or new-old-stock, so you may have to do some searching if your Mustang needs one.
16 With our rebuilt air box...
16 With our rebuilt air box back from CAA, Gil manipulates it into place. Unlike the '67-'73 Mustangs, you don't have to fumble with a heavy unit and cumbersome underdash access.
17 There are three brackets...
17 There are three brackets that support the unit - two on top and one at the lower left.
18 Three new studs penetrate...
18 Three new studs penetrate the firewall and are secured using a 13mm deep-well socket.
19 Fan speed is changed with...
19 Fan speed is changed with the humble, hardworking resistor pack. It's actually a variable resistor, which provides different resistances to ground. This approach to controlling blower speed is the same from '65 through '13. Resistance coils are located in the air stream for cooling purposes because they get hot.
20 With the climate control...
20 With the climate control package installed, Gil reinstalls the dashboard, which has been repainted with black vinyl paint with a flex agent. This is a modular bolt-in dashboard, which dates back to the '69 model year when Ford first installed bolt-in dashboards.
21 The climate control switch...
21 The climate control switch assembly is a no brainer because all electrical, mechanical, and vacuum connections are fool proof.
22 The 5.0L engine's compressor...
22 The 5.0L engine's compressor bracket gets a 3/8-inch hole to accommodate the Sanden compressor with CAA's R-134a conversion.
23 Gil uses a reciprocating...
23 Gil uses a reciprocating saw to trim the bracket's access. This actually improves aesthetics.
24 The Sanden compressor...
24 The Sanden compressor is installed with all bottom ears outside of the brackets with provided 3/16-inch thick spacers between ears and brackets.
25 R-134a specific O-rings...
25 R-134a specific O-rings are lubricated and rolled on. Your fingers must be hospital clean. Any debris, no matter how small, can cause leaks.
26 This orifice tube/filter...
26 This orifice tube/filter slides into the liquid line on the right-hand side of your engine.
27 Here's the installed receiver/dryer...
27 Here's the installed receiver/dryer tank (also called the accumulator), which demonstrates a perfect drop-in replacement for the factory unit. Note the pressure switch, which utilizes the factory connection.
28 R-134a specific refrigeration...
28 R-134a specific refrigeration lines have the high side service connection in red. Make sure these lines clear exhaust headers by a wide margin. In fact, it is suggested you use a rubber lined Adel clamp to tie these lines to the right-hand frame rail.
29 The Sanden compressor...
29 The Sanden compressor has an eight-rib pulley, which will work with your six-rib serpentine belt. Just make sure the belt is centered.
30 When installing heater...
30 When installing heater hoses (not supplied in the kit), be sure to use the restrictor in the supply side heater hose to reduce volume and pressure to the heater core. Excessive volume and pressure has caused countless Fox-body heater core failures.