Silverado Evaporator Replacement Trick (Replace Without Removing Dashboard!)

Remove your evaporator without the tedious and long process of removing your dashboard

[@daveharmon8674]

I've been watching KZbin for 20years now and I must say that this the Best Video i've ever seen!!!!

[@440Nichole]

damn , you were watching youtube 5 years before it came out . awesome .

[@f1346m]

I like your idea and find it very useful. If this is your vehicle and want to take this shortcut without caring about cuting of peaces of the dash go for it. It's your truck and you do whatever the heck you want with it period.

[@buzztrucker]

I am not an expert mechanic. I finally saw a lot of the comments (positive & negative) on here. I tried to come up with a solution that removed the tedious steps of removing the dashboard. The plastic could have been cut better but I was able to seal the plastic and reattach everything and there's no drip. You don't need the metal bar I cut out to reattach the glove compartment. Again, I'm not an expert and I might not know the tool and requirement names perfectly but my ac is blowing cold and I didn't have to remove my dash to fix it.

[@f1346m]

buzztrucker great job and very smart if you ask me.

[@Mustacheologist]

I did this same job this same way. F these losers paying some cheat $1600 to pull their dash. Dremel multimax for the winnnnnnnnnn

[@daniel.dsanchez.9456]

Mustacheologist ,

[@dirkaelder]

This is great. I am doing it this way. I don't really care about the resale value on a 22 year old truck.

[@buzztrucker]

I don't know squat about cars. I just try to look up youtube vids and if it's manageable I attempt the fix otherwise it's to the shop. Been getting a lot of static but I didn't really have all the right tools. That cut wasn't to great but my AC works great now and at a fraction of the price an autoshop would've charged.

[@gabrielseaff487]

Hey friend. I saw your video. Despite all bad comments posted, I must tell your idea was great. I used your idea to change the evaporator in my truck. I used a hot knife to pierce a hole and then I used a hand-saw to cut through the box's front. I cut it off like a lid. Clean cut. I replaced the evaporator. Put the lid back on and covered it with a silicon-sheet. Came out perfect. Thanks so much.

[@buzztrucker]

Yeah I actually in retrospect has a friend who said I should have used a hot knife for precision. That's the only botch part about the project but I was able to seal the drip tray and get everything attached back properly.

[@mikedagostino6318]

Good video, I was also quoted $850 to replace the evaporator. He said there's no other way to get to it other than pulling the entire dashboard out. Well now I know there's another way awesome! 👍👍

[@mariop3519]

Buzztrucker, right on man! This is freaking awesome. Been rebuilding salvage for years now and sometimes the best path is a straight path that makes sense. I'm going to take just a tad diff approach on the metal cut. What I'm going to do is cut the plastic pieces first, then make the metal cut smaller. When I put it back together what I'm going to do Is weld back the metal first with my 210 welder, grind it perfect, hit it with self etch primer and then plastic weld back the plastic, heat it with a heat gun and use some grey interior paint and done. That'll take me 40 minutes at most. You're idea is really smart, just because the they built this truck ass backwards doesn't mean we should wrench it that way. Keep on keeping on!

[@deeppurple3489]

I like your idea! Plastic weld the plastic back together and then get my son-in-law to weld the metal back in place. Then it's all put back in place without tape that could let go. I'm in the process of installing a retro cabin filter kit in as well just right of the evaporator. I've a 2003 Silverado 2500HD. I feel if you can keep the crud off the evaporator it won't go bad.

[@albertoreyes9704]

Traibazer 2003 is work??

[@albertoreyes9704]

Traiblazer 2003 is Work

[@lastchancevideos5949]

Can I use this method for heater core replacement?

[@joyjastyle01]

It worked for me i used one of those drill attacments with the abrasive cut off wheel, only key is to wiggle the evap coil up and down when trying to remove it after the cut , and make the cut wide enough, your gonna have to tape it up anyway. less resistance coming out or going in the better. I now have AC in 2003 chevy suburban thanks for building my confidence in trying this (came out great you can't tell at all i hade ac problem)

[@zackk695]

As far as the drip tray goes you just have to make it waterproof which a two part epoxy could easily do for less than $10. The sides of the box can be tapped permanently with good ol fashioned ac tape which works very well and will allow you to take it apart again in a few years to clean the coil. At first I thought it was a butcher job but its actually not a bad idea as long as you change the accumulator and orifice tube along with getting it vacuumed properly

[@geneborne5]

That is such an obvious solution to a otherwise major project. Thanks for the video. GM engineers could have easily incorporated a "passage way" to replace that core. Mine is a 09 duramax so I'll be studying the potential of this brilliant method. Thanks !!

[@buzztrucker]

There's a better way to do it with a heat knife instead of the tool I used. I have no experience in doing anything car related. I only know how to change my oil, my oil filter, my cabin filter, and just recently I changed the alternator on the truck. The patch job I had to do sucked because I could have been more surgical with my cut and used a heat knife. Anyone on here giving me negative comments should keep that in mind. I was trying to save a lot of time and I did rather than having to completely remove the dash.

[@KleeEditz]

Will you show a pic of the finished product? Also how did you get the plastic bottom piece to drop I’m about to do this job

[@lesant3131]

thank you so much for making a clearer video.. this helps tremendously....

[@buzztrucker]

I also removed the cabin filters to help make removing the evaporator easier. If you have any questions please post them and I'll try to answer them as soon as possible.

[@Tigersfan829]

buzztrucker I have everything loose but my evaporator is hitting that plastic flange that sticks out from the top and I don't see any other way to get it out besides to break it. Did you run into this problem?

[@jasonbooth5141]

If GM would have put an accessible door or someone have an aftermarket housing to access this much easier that would be fantastic

[@jeanetteivy5229]

Yes indeed it would!!!

[@aww4954]

Engineers...........

[@Lady-Carmakazi]

@@aww4954 deliberately done so most won't attempt working on it themselves thus insuring the shops can still make money off a $90 part by charging $700+ to install.

[@Lady-Carmakazi]

Deliberately done so most won't attempt working on it themselves thus insuring the shops can still make money off a $90 part by charging $700+ to install.

[@nycboy121]

Do you have a video showing how you sealed everything back up?

[@brennengoude970]

Does the drain line attach to the evaporator?

[@Truthseaaker]

How far in there is the evap temp sensor?

[@theretrodad8716]

Dude.. Just did this on my 96 GMC C1500. Pretty much the same deal. Thanks for the idea!! Now I just need to figure out how I make it airtight after its all put back together.

[@katherinefaith7912]

My car is valued at about the same price that mechanics were asking for to replace the evaporator core in my 2002 Dodge Stratus. I do have a couple questions for you, primarily about how you were able to replace the plastic square you cut out (since the box I'm sure needs to be sealed to the best of its ability) and if you had any leaking problems after cutting the drainage basin?

[@buzztrucker]

None. I used silicone sealant and duct sealant. I know I didn't do the best job and a hot knife would have been better. I just cut way too low. My recommendation is to just cut with more care and precision.

[@athenamarangos9642]

So this video that your showing is that the evaporator removed only ? Did you have to cut or do anything extra to the glove box ? That would make you have to jimmy rig it back together

[@dennisboxerman4748]

Great Video. Love the fact that your are so creative in finding an effective way to do the job and save hundreds. Guys like me really appreciate you for sharing the knowledge!!

[@JM-yx1lm]

Absolutely no knowledge was used or put forth in this video. Get real dude.

[@s.t.k.r.]

Why does everyone think it costs money to remove dash?

[@chevyvantravel9735]

what were the symptoms?

[@SuperKiller177]

Did you have to take off the a/c bottle?

[@daveharmon8674]

Do you think that this would work for getting my heater core out also. I seen a Video where it took a guy 20 hrs to do a Heater Core. I think he had bolts left over also.

[@86Chevymontecarlo]

I wish. I did the full deal (heater core and evap). Took me 12hrs (in between breaks and tempering my rage). I also made sure I put the same amount of bolts in as I took out.

[@ministerfrank4Christ]

Did you make a video showing how you put everything back?

[@jcee25000]

Will this work for a 98 Chevy 1500?

[@douglasmueller4684]

Yep going through the same thing now. Did the heater core this way too. Thanks.

[@CynicalDad81]

Is the heater core in the exact same hole?

[@douglasmueller4684]

@@CynicalDad81 its not the sane hile but it's in the same box. It

[@devinalba3367]

@@douglasmueller4684 Where did you cut to get to the heater core

[@douglasmueller4684]

@@devinalba3367 I believe it was a small cu at the bottom. Tinley it slide out. Was not to bad..

[@kevinhernandez1151]

Hey I was wondering if you could make like a video or post some pictures on when you put the glove box compartment back on .to see how you bolted it on.

[@buzztrucker]

It's not hard. I just bolted the hinge back on and the original screws except one I believe it. Still works just like it before I removed it.

[@Mustacheologist]

He didnt cut out any part of the bracket which the compartment screwed back into. Merely the one bar that stretches from left to right...

[@richardpayne5164]

Kevin Hernandez

[@roberthadaway8290]

Pulling a dash on these trucks is really hard. I'm in the middle of one this week on a restoration of a 97 suburban . Had a good laugh about how much easier it could be. I've been thinking about this video as I pulled mine. I'm making a video of the process to post here. I had a broken mode door so this wouldn't have worked even if I'd wanted to take a saw to my plenum.

[@sparkone007]

What a hack. Zaw sall. Lol. Unreal

[@marvstevens4013]

hey its the zaw saw dude

[@bmw740boy1]

Great video at least he tried all the negatively don't help he just making a video for certain people maybe just maybe everyone don't have the money to bring theirs to a shop

[@flipbales5904]

I'm about to try this on my 2000 Suburban so I've been researching this, and I can tell you this is what I'm going to try, my truck just isn't worth the money to take it to a shop. Anyway thanks for the video, I didn't find the second, how did it turn out in the end?

[@pilgrimhere652]

I have not taken or removing much of my pick up to reach and remove the evaporator, I cleaned it and also bought a new circuit thing and tomorrow I'll test it and put everything back , take it to the technician to fill it with air free on gas and ready , Thanks to u-tube mech university friendly teachers, Good job by all people here show how to do it your self , Car jobs cost too much.

[@iram.473]

Somebody please give this man a beer!

[@MrLosgonzalez87]

This was 7 years ago how is the ac working with the parts from geek parts?

[@wadetaylor9974]

Great $ saving diy tip. Nice job.thanks.....

[@davidmarrocco2555]

will this work on a 1998 gmc

[@lucascranston2288]

This is awesome for an older vehicle. I saved the plastic and used a generous amount of silicone to seal it back up. saws all 😀

[@bcjdwbiernfjherwfbowfib]

Lucas Cranston so did you do what he did and replace the evaporator coil? And if so, were you successful?

[@buzztrucker]

Yeah I used Silicone sealant and it hasn't leaked. I did save the plastic too which I probably didn't mention in the video. Everything is back in place and the AC blows cold. I've used SAWS ALL ...( I get it now) maybe but like 3 times ever before this. I guess I had all the corrections coming on the spelling. The only thing I recommend is to use a hot knife for more precision, but the project despite having to be more careful in putting it back together was a success.

[@ricardoubaldo2677]

Man, thats all we want, drive this beautiful truck with ac, all around, thank you great job you guys right on

[@jacaughron55]

Do ducks have to die for tape?

[@johngodwin7902]

Are you able to put the glove box back on when done?

[@buzztrucker]

Yes. The hinge will go back on and you can mount the glovebox to it even with the cutouts.

[@warbed1]

Ok truck isn't worth putting a lot of money into,I can understand that. I have a work truck 94 1500 and had the same concern, I did the evaporator core the correct way and then 3 months later it went out again. So like you I thought there had to be a better way. New truck was not in the cards. Lucky Evap was still under warranty but not so lucky on the labor. So made a template of the core and drew it on the bulkhead (some call it the firewall but that is not correct) took my metal saw and cut the bulkhead and then the Evap case. pulled the Evaporator out the engine side. Through out the plastic and put the new core in, then put a sheet of fire resistant insulation (no such animal as fire proof) . used the metal I cut out to make a oversized metal cover and now if I ever have a concern with the Evap core it takes less then 15 minutes to replace. And yes it is sealed and no gasses from the engine get into the interior. Maybe I should make a video

[@liljujube22]

warbed1 make a video

[@AquaLady153]

Make a vid! Make a vid!

[@jeremymcfadden7473]

BarberChop VIDEO!!!!

[@julus0789]

Make a video!

[@mattsouza4395]

This wasn't the hack video? U can do worse than this please post

[@douglasmundle5356]

Cost $100 how long ago was this I cant get the core for less than 140.00

[@jamesfayad6093]

Dumb question but will this work with a 99?

[@joemamma4324]

YUP

[@williamparson7702]

Pretty good video....I have a 2000 Silverado two wheel drive....I've been trying to figure out how to change my heater core without taking my whole dash out....your video helped with that...plus you can hide the cuts with the glovebox...

[@bigmike7939]

William Parson were you able to change the heater core with this method?

[@mandosgarage]

There’s a plastic welding iron that will work so we’ll with this

[@kenjiwest]

I was just quoted $3400 to replace the evap core on a 2013 Tahoe LTZ. WOWZA !!!

[@jaredphillips889]

Pulling mine monday. 07-13 silverado. 1200$

[@johnvickers6280]

I hope this video is right as my truck is a 93 2500 GMC here goes nothing everything is new but the E vap

[@garykreil5990]

Well I have a 2015 Chevrolet, high country to boot!!! And I need to access this, this is going to be interesting.

[@dessierodriguez3885]

i did this and the air doesnt come out thtew the vents anymore?

[@xboosh]

zaw sawled lololol

[@sergiozamorano6413]

I rather cut my truck dash than been melted like butter in the arizona heat good video 😂

[@tigertoilet2]

laposcopic surgery for the truck. i like it. it works . its easyier . and i love my saws all anyway.

[@nycboy121]

Did you have to do anything to the AC system before pulling out the evaporator?

[@buzztrucker]

No.

[@nycboy121]

@@buzztrucker thanks I'm going to do this myself but I'm just worried about sealing it all back up.

[@buzztrucker]

@@nycboy121 I was sloppy about it and yeah I don't know tool names. I'm not a mechanic in the slightest. I sealed it up nice though. I would just be careful to be precise when cutting the plastic housing.

[@nycboy121]

@@buzztrucker how did you seal it up?

[@Fonzorelly86]

Does this process work on hummer h2 2003?

[@johngabriele6532]

I have to say... I'm currently replacing every a/c part in my wife's 1995 suburban... Everyone says it's not worth $800-1,500 to fix things on their vehicles that are only worth so much... My question is ???? If it's not worth that much why don't you go buy another one then.... By the time you do you could have more into buying another used vehicle or you could have brand new parts that could last another 15-20 years ... Not to mention you know what you have then...

[@bcjdwbiernfjherwfbowfib]

Were you successsful in the end?

[@buzztrucker]

Yes. A/C blows cold and drip tray was sealed and I reattached everything including the glove compartment.

[@bryanwhat2268]

ha ha ha this is great the quick way of replacing it I think ill just pay some one to fix it

[@albertoviamonte5348]

i have change the mine

[@TheTortugitaTURBO]

good vid but im just gonna take it apart!

[@roberthadaway8290]

What did you end up doing?

[@TheTortugitaTURBO]

@@roberthadaway8290 i pulled out the whole dash board. His way works to. But i didnt wanna cut.

[@bayou-buy-me]

I did my 2001 the right way and had problems with 22year old plastic crumbling, so reassembly was patched along the way with improvised reinforcement,..no way is it a few hours work. People saying that have never done the job.

[@shroomze]

its not the same design threw the years as you said, there used to be a cabin air filter...

[@cesarlaso356]

Can the heater core be replaced with this method? This only looks bad because the hole cover is in pieces. A complete cover, silicone sheet on the tray, AC tape to hold the cover, and it's a genius idea Instead of a hack. Great solution for a an 15-20 year old vehicle.

[@buzztrucker]

cesar I don't think the heater core can. It requires you to remove the complete dashboard unless maybe there's a way to cut into it like I did.

[@omoffroad]

This guy "Zaw Sawed" his truck and ruined it. Can you imagine buying this truck used and discovering this hack job later on?!???

[@magnumdubstep8765]

i agree, my truck's heater system needs to be looked at and i am not doing it like this

[@lokofreestyle5430]

he did what he had 2

[@jesusmercado6947]

omoffroad this hack job just made it worse on value this truck won't be worth anything

[@hillbobaggins]

loko freestyle he didn't do what he had to do. He purposefully chose to do a bootleg ass repair.

[@lokofreestyle5430]

Jason I don't see what the problem is, he got the job done.

[@frescabigblock]

where the hell do you buy a zaw saw?

[@brianhambrick9023]

Life saver

[@jcjammer1]

Angle grinder would work also. Just be careful not to catch nothing on fire. 😂

[@Rough-Rider]

did your a/c blow cold after you hooked up everything?

[@buzztrucker]

Yes it did. Only things I would have done differently. Used a hot knife and taken more time to cut with more precision. AC blows cold and all the pieces are back together.

[@86Chevymontecarlo]

I had to change my heater core on my `00 Tahoe and went after the evap and blend door actuators as well. Took 12hrs. Hated life afterwards. A lot of folks don't understand how much of a pain it is to get to these items. So it's easy to complain or mock your video. Your way is cut and dry. You either do it or you don't.

[@waynegretzky8464]

Thank you seriously these people dont do big jobs by themselves often i can see and all you do is weld that crossmember back in the plastic is all cosmetic! Good job dude!

[@waynegretzky8464]

Me n my dad are notorious for our "access ports"

[@kburrolopez7160]

Nice

[@FMChimera]

Considering the current market your $3500 truck is now worth about 6k :)

[@txslugg7318]

Why not cut from the front instead from the dashboard?? There is metal glue for that would of been alot easier

[@jamesfusco4056]

Evaporator another name for heater core??

[@r.stieffel3744]

No that's two different things. Heater core has engine coolant running thru it.

[@rahrah8076]

no...this is a.c. evaparator not a heater core where coolant enters it

[@geostanley409]

Don't buy a gold chevy extended cab with air conditioning from Florida! 😂😂😂

[@DavidSmith-mk7qo]

Hey I think I bought that truck LOL

[@DavidSmith-mk7qo]

LOL it is still intact.Thank God!!!

[@jesusmercado6947]

Geo Stanley lmao

[@TYTHONGDETH]

any truck could happen I own a 1998 siverado but it dont break

[@TYTHONGDETH]

that is 21 years

[@johngabriele6532]

Oh by the way not bashing ... Lol I enjoyed the video ... If it was my beater banged up work truck that employees are just going to trash I would do this over and over....😜

[@moneymac2864]

its called 'saws all' because it saws all...

[@WikkedR1]

Nope. It’s called a zaw-saw because while you can use it for other materials, it’s specifically engineered to saw zaws. 🤣🤣🤣

[@ennyrrivas7627]

Esto nos muestra exactamente lo que no hay q hacer 🥴

[@webrik33]

no thanks i'm not cutting up my truck like this

[@timothyallencottrell9643]

If it’s 2008 and under no one would even know it and it cost u less unless you’re rich and burn money? This method a lot quicker for family’s in short income and it’sa affective my ac get a to 39degrees this way I have many brings me their vehicles to be cut open and ac fixed any way necessary I guess it depends on money and heat index

[@s.t.k.r.]

​@timothyallencottrell9643 this is old I know but why does it cost more money to pull and replace dash?

[@bigmike7939]

Can you access the heater core that way also?

[@buzztrucker]

85% sure you can't. That's a hairy job. I would advise you take it to a shop because you're going to have to do a lot of disassembly and reassembly.

[@bigmike7939]

buzztrucker that’s what I figured but thought I would ask anyway thanks

[@alexprice1443]

I had to check the comments to see how many people corrected the "zaw saw" thing... And critiqued his hacking through the dash

[@hebertfly]

Sweet, nice job

[@Thefishingplumber]

2014 Silverado was hissing lost all Freon compressor wasn’t turning, this was the issue 850 bucks

[@mastersword131]

Spent $1300 to replace ac compressor and some hoses and recharge at a shop, within the week it stopped working and was quoted $1100 to replace this, guess it’s time to cut up the truck.

[@buzztrucker]

I'm no expert and I tried my best. They make plastic cutting swords that through plastic that would be more precise and surgical. Now I know it's a SAWZALL! LOL. I have little to no experience and I tried this on my own and given the age of these trucks it's not worth it to pay that much! Best of providence in your task.

[@csb772]

Hey I used a saw to cut out my whole dash and I am a great mechanic!! But of course it is now a dragster!!!! LMAO!!!!!!

[@dannyoconnor8730]

A rotary tool is not basically a dremel

[@s.t.k.r.]

I understand if you are in a pinch about to go on vacation or a trip in a few hours ok. But pulling dash is not that hard. Either way got to get ac refilled. It costs nothing to pull the dash if you have tools. My thing is if you are not mechanically inclined to do the job correctly you're probably not going to be able to do this hack and leave it alone. Save money get it repaired correctly. Once you mess it up a 800 dollar repair will be a 2k repair. And for 50 bucks replace heater core while you are at it. Blow everything out and check recirculation blend motor.

[@buzztrucker]

Repair worked. No leaks. AC blows ICE COLD. I'm not mechanically inclined. I just watched some hacky vids and figured out the dissection. This hack cuts the dash removal time which drastically reduced job time. My truck is probably (at least back then b4 inflation and coronavirus) worth not even 4-5k. It's got over 200k miles on it. Time is money. It's not worth the extra time for me with how much I make hourly and the value of the the vehicle to remove the dash. If people have the luxury of time then there's plenty of dash removal vids. God Bless You.

[@damxgopak457]

I charge 1200 for taking out the dash giant pain in my own truck I cut it out too.

[@recorptnh]

that and the heater core.... a pain in the ass.... i would do this on 250k + miles truck... where its closer to the junk yard life than anything..... if any of yall are doing it on a 100k-ish miles truck... then yeah thats a hack u dont want to do... yet

[@shawnguthrie1695]

#Unpresidented #TacoTrucksOnEveryCorner man I have a 2002 with 278 I'd never do that I grew up working on cars some things I don't know but I figure it out

[@bracketracer2000]

who cares about correctness? hes a genius....thanks for the vid I have to change mine this weekend

[@pedrosaldana5568]

Barry Green

[@timothyallencottrell9643]

How did the change go did u do it this way?

[@viivcreations9161]

idk why the fuck gm never put a door or something to make this an easy job -.-

[@dirtyboy8336]

Man that's nice u took it in your own hands but that looks F-Up

[@wontsay7923]

It's not Zawzaw. Saw zall. Just say reciprocating saw.

[@erikwright7437]

Ive got an 03 1500pickup. And cut an access panel to the heater core and installed a hinged door in my bed to access the fuel pump as. Fuk it. Cut it.

[@hamyncheese]

in 2022 inflation and shortages dollars, your truck is probably worth 6-8000 USD

[@angkhane98]

man, all these perfect pos people with negative comments... smh... GREAT VIDEO

[@kccarl2582]

Zaw saw lol

[@enfamy_OG]

Yeah dont worry about having air leaks, also just let the evaporator drain onto the floor. Duct tape it up, screw it

[@andrewwastien]

this video was long time ago before bideinflation I don't wanna know how much will the shop charge in 2023 🤣 like the guy said if the truck is worth 3000 you don't gonna expend 800 dollars on it unless that the work needed is crucial for the vehicle

[@steveashcraft718]

As a retired mechanic no way would I do something like this. Do it right or not at all.

[@jeffentrekin4283]

It is called a reciprocating saw or "Sawz-All" not zawl saw as u said.And Oh MY GOD- I wont even comment on the INCORRECTNESS of this "procedure"