1)- Remove light bulb from passenger side footwell, or disengage by removing it's fuse. This light gets hot, and will burn your arm quite nicely (my second syclone related injury).
2)- Remove passenger side footwell trim panel (7 - 9/32 hex screws). Its that dark plastic piece just under the dash.
3)- Remove passenger side kick panel (4 - phillips head screws).
4)- Remove ECM (1 - 9/32 hex screw). Remove the screw, and carefully pull it out from under the dash. You'll need to unplug it from the harnesses, and place it somewhere safe.
5)- Remove Ash tray
6)- Remove Radio Trim panel (3 - phillips head screws) The cigarette lighter simply comes off by spreading the two plastic arms away from the shaft on the back side of the trim plate.
7)- Remove Radio. (2 Hex bolts) Remove the bolt on the far right and left brackets, then pull the stereo out, unhook the wire harnesses and antenna wire.
8)- Remove access panel in the rear of the glovebox (2 - phillips head screws)
9)- Remove bolt on passenger side of truck that holds onto the dash (1 - 10mm Hex bolt)
10)- Pull out on the bottom of the dash, moving it out, and down to hook it on the tab that it was screwed into. This is to aid in removing the Heater core cover that needs a little room to move.
Step 4: Removing the Heater Core cover
1)- Removing the screws (6 - 7mm hex screws) Four are easy to get to from under the dash (2 on bottom, 2 on right side). The top screws are accesible through the radio opening, and one in the glove box opening. These are the real pain of the group. Have fun, don't loose the screws
2)- Disconnect the Heater Vent Hoses that are connected to the top of the cover.
3)- Begin Yanking! Pull on the heater core cover from the bottom right side. (towards rear of the truck). Then try to move the cover to the right to disengage it from the ducting on the left side.
4)- Cut the tape. There is some sticky foam stripping in the joint between the rest of the ducting and the cover, Cut it at the bottom(under the dash), and at the top (from the radio cavity).
5)- Rotate the cover so the bottom goes toward the front of the truck, and the top, towards the rear. This is to get it around the heater core that rests inside. You'll have to pull the "T" shaped ducting (look through glove box) out of the top of the cover to get it out. Be careful, its plastic. It will come out, just be nice, and wiggle till you manage to get that SOB out.
Continued on next post.