Ford Bronco 1968, Bronco 1969, Bronco 1967 Installation Manual

DOCUMENT #1-1078

©2018 ClassicAutoAir / 12.18

1969-67 FORD BRONCO

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You have just purchased the highest quality, best performing

A/C system ever designed for your vehicle.

Congratulations! ! You have just purchased the highest quality, best performing A/C system ever designed for your Classic Car. To

obtain the high level of performance and dependability our systems are known for, pay close attention to the following instructions.

Before beginning the installation check the box for the correct components.

Evaporator

Face Duct Assembly

Inlet Air Block Off Assembly

Firewall Block Off Assembly

Flex Hose 2”dia. x 3ft.

Flex Hose 2”dia. x 4ft x 2ea..

Flex Hose 2 ½”dia. x 2 ft.

Sack Kit Louver

Sack Kit Hardware

Sack Kit Control

Glove Box

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Check List, Pre-Installation:

Procedures, During Installation:

Before beginning the installation check the shipping box for the correct components. YOUR BOXED UNIT INCLUDES A LIST OF
MAJOR COMPONENTS AND A LIST OF BAGGED PARTS. We have a 5 stage check process to make sure you have everything you’ll
need.

If your vehicle has been or is being modified, some procedures will need to be adjusted to fit your particular application.

A basic cleaning of the engine compartment and interior before beginning will make things go more smoothly.

Check condition of engine mounts. Excessive engine movement can damage hoses to A/C and/or heater.

Before starting, check vehicle interior electrical functions (interior lights, radio, horn, etc). Make a note of anything that does not work as
it’s supposed to. During the installation you might find the opportunity to repair or upgrade non-working or out of date components.
When you’re ready to start the installation, DISCONNECT THE BATTERY FIRST.

Drain the radiator. Retain the coolant and reuse, or dispose of properly.

SAFETY FIRST: Wear eye protection while drilling/cutting, deburr sharp edges, and never get in a hurry or force a part.

Tools: Your installation only requires the basic tools everyone has in their garage, nothing exotic or specific to A/C or Heat equipment.

Fittings: Use one or two drops of mineral oil (supplied with your kit) on ALL rubber o-rings, threads and where o-rings seat in fittings. Do
not use thread tape or sealants.

Measure twice (or more), cut once

Should you have any technical questions, or feel you have defective components (or missing items), call us immediately,
we will be glad to assist you. Our toll-free number is listed on every page, we’re here to help!

CAUTION: DISCONNECT BATTERY GROUND CABLE

YOU CAN NOW BEGIN THE INSTALLATION...

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The air conditioning system in your car is comprised of a compressor,

condenser, expansion valve, receiver/drier, and evaporator. Refrigerant (also

known as Freon) is compressed in the compressor. In the condenser, gas is

cooled to a liquid state and travels to the expansion valve. As the liquid refrigerant

goes through the expansion valve it rapidly cools in the evaporator. A fan blows

over the evaporator and cools the air that blows out your vents

Evaporator with Blower Fan

In order to remove the heat from the air in the vehicle,
the A/C evaporator allows the refrigerant to absorb the heat from the air passing over it. The blower fan
moves cool air out into the car interior.

Compressor

The compressor pumps and circulates the refrigerant through the system.

Condenser

The condenser is a heat exchanger mounted at the front of the vehicle. Heat drawn

out of the interior of the car is expelled here.

Receiver/Drier

The drier not only dries refrigerant, it also filters the refrigerant and stores it

under certain operating conditions.

High Pressure Switch

A pressure switch is used to shut down the system if high or low

pressure is detected, basically it acts as a safety switch.

A Basic Overview of Automotive A/C....

Receiver

Drier

Compressor

Evaporator Unit

Expansion Valve

Condenser

Suction

Valve

Discharge

Valve

Firewall

OUTSIDE AIR

COLD AIR INTO VEHICLE

AIR FROM INSIDE VEHICLE

GROUND

POWER

SUCTION HOSE

DISCHARGE HOSE

LIQUID HOSE

1

1

2

3

4

5

2

3

4

5

COOLED AIR

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“PERFECT FIT SERIES”

IN-DASH

HEAT/ COOL/ DEFROST

CONTROL & OPERATING INSTRUCTIONS

The controls on your new “Perfect Fit” system. Offers complete comfort capabilities in virtually every driving condition. This includes
Temperature control in all of the modes.

THE PICTURE YOU SEE ON THE FIRST PAGE SHOWS THE CONTROLS IN THE FACE MODE. THIS MEANS THAT THE AIR WILL BE
DISTRIBUTED THROUGH THE FACE OUTLETS. THIS ALSO HAS THE TEMPERATURE KNOB IN THE COLD POSITION. WITH THE
CONTROLS IN THIS POSITION YOU WILL GET THE AIR THROUGH THE FACE OUTLETS WITH THE COMPRESSOR ON.

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CAUTION: ALL OF THE OUTSIDE VENTS MUST BE CLOSED WHEN THE SYSTEM IS IN THE A/C MODE. THIS WILL ALLOW THE
A/C SYSTEM TO FUCTION AT ITS MAXIMUM PERFORMANCE LEVEL.

THE FOLLOWING SUMMARY WILL DESCRIBE EACH OF THE CONTROL LEVERS FUNCTION.

FAN SPEED SWITCH: There are 3 speeds plus Off. When the switch is in the off position it will disconnect the 12V power to the
Blower Motor and the A/C Clutch. This will shut down the entire system. When the switch is moved to any of the blower speeds 1, 2 or
3 there is 12V supplied to the Micro-Switch that is mounted on the main housing.

FACE AND FLOOR / DEFROST MODE: When the push pull cable is pulled all the way OUT, it will direct the air to the floor / and defrost
ducts. The cable can be moved any position from full in to full out. This will give blend between all distribution outlets.

TEMPERATURE CONTROL: The temperature Knob as shown is in the COLDEST temperature position. As the lever is pulled out the
temperature of the discharged air will rise to the HOTTEST point.
Note: The temperature lever will function in any of the modes.

AIR CONDITIONING MODE: The picture shows the Knob in the Face Mode (air-flow out the face outlets).
When the Mode control knob is pushed all the way IN the Air Conditioning is activated the compressor clutch is on. When the com­pressor is activated the Temperature Lever will control the air from maximum cold through maximum heat.

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Disconnect the battery ground cable.

Drain radiator and disconnect Heater hoses from the heater connections on engine
side of the firewall.

Remove Glove box door, and glove box. Retain the glove box door and all original
hardware.

Discard the glove box housing.

Located behind glove box are the defrost duct hoses. Remove the entire hose and
discard.

Disconnect Heat/defrost control cable from the heater. Discard the hardware.

Located on the firewall in the engine compartment (4) Hex head nut and washers.

Remove and discard.

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Remove the heater. Discard flexible air tube to the air inlet flange.

Lay heater on the floor and disconnect cable to the fresh air door.
Discard the hardware.

Disconnect electrical harness from the resistor and blower motor.

Remove the inlet air flange. Discard flange and original mounting hard­ware.

Locate the air inlet block off and (4) #10 x ¾” tek screws.

Attach the block off over the inlet hole as shown, using (4) #10 screws.

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Remove the radio, and control assemblies.

Blower switch removal requires the knob to be removed. Discard knob.

Remove nut from front of the blower switch, retain trim ring, and discard switch
assembly. The brown wire attached to the switch is the power for the new heater and
a/c unit.

Remove remaining (2) controllers from back of the panel by loosening the nuts.

The controllers that were removed from the panel need to be modified.

Clamp the cable into a vise and cut the cable as close behind the trim ring as possi­ble.

Discard the knob, and cable. Retain the trim ring.

Using a soft cloth so as not to damage the ring. Clamp the trim ring and drill center of
the ring to 7/16” diameter.

This will allow the new control cables to fit through.

BROWN POWER WIRE

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Locate the new controls and blower switch from the control sack kit.

Remove the first nut and position the back nut ¼” from the end of the threads.

Install blower switch with the blower trim ring through the center hole and attach
with the switch nut previously removed.

Be sure switch is in the off position and the flat is pointing down.

Locate the control cable assembly with the ring on the end. Attach cable through
the left hole along with the “Temp” trim ring. Use the switch nut provided.

Locate the last of the control cables and the “Defrost” trim ring. Attach cable
through right hole and the defrost trim ring. Use the switch nut provided.

Attach the knobs provided using an allen wrench as shown.

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Locate the #1 template from last few pages of the installation instructions.

Attach to the dog house and drill (2) holes 5/16” dia. as shown.

Locate the #2 template.

Attach over the (2) original heater mounting holes. Drill (2) 1 ½” holes and (1)
11/16” hole as shown.

The modifications to the vehicle are complete. You can now begin installing your
new Classic Auto Air “Perfect Fit Series” system.

Locate the Evaporator Assembly. Place on work bench.

Remove drivers side heat dump and discard the dump and the hardware.

HEAT

DUMP

ORGINAL HEATER MOUNTINGS

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Locate 2” dia x 24” (1pc), 2” x 36” and 2” x 48” flex hose from the unit box.

Cut (1) pieces (1) 20” long, (1) piece 35” long, and (1) piece 45” long.

Attach over the outlets as shown.

Locate (2) 2 ½” to 2” flex hose adapter and (4) #8 x 3/8” pan head screws from the hardware sack
kit.

Attach to the ends of the 20”, and 35” flex hose. Using (2) of the #8 screws for each connection.

Locate the blower support bracket and (2) #8 x 3/8” pan head screws from the hardware sack kit.

Attach bracket to top of the blower motor as shown, using the (2) #8 screws.

Locate the wire harness from the unit box.

Route the harness over top of the unit and connect blue wires to the thermostat and micro switch.

Other end will plug into the blower motor connector.

Long blue wire is the clutch wire. This will go through firewall out to the compressor .

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REFER TO WIRING DIAGRAM BELOW

Remove the ¼-20 j- clip from top hole on rear mounting bracket next to the blower assembly.

Locate the rear Evaporator brace assembly and (1) ¼-20 x 5/8” bolt from the hardware sack kit.

Loosely attach brace to lower hole on the unit bracket.

REFER TO WIRING DIAGRAM BELOW

REF

ER TO

WIRING DIA

GRAM

BELOW

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Carefully slide unit behind the glove box.

Locate (2) ¼-20 x 1” hex head screws.

Attach drivers side of the unit through holes in the firewall
that was previously drilled, and into the ¼-20 j-clips as
shown.

Locate (1) #14 x 3/4” tek screw from the hardware sack kit.

Holding evaporator level with edge of the dash attach
blower bracket to the air box using #14 screw as shown.

Locate (1) #10 x ¾” tek screw. Attach ground from blower
motor to body next to the blower support.

NOTE: The routing of the flex hose and the door cable.

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Locate (1) ¼-20 x 5/8” hex head screw from the hardware sack kit.

Insert screw from engine side of firewall and attach to the rear support brace.

Tighten the screw on back of the unit.

Route 20” flex hose with the hose adapter to passenger defrost diffuser. Attach
adapter over
diffuser using the clips on the adapter.

Route 35” flex duct with the hose adapter to drivers defrost diffuser. Attach adapter
over diffuser using the clips on the adapter.

Locate the remote heat dump and (2) #10 x ¾” tek screws from the main box.

Attach heat dump to firewall just to left of the clutch pedal using (2) #10 tek screws.

Route 45” flex hose over the steering column and attach to the heat dump.

Locate (1) #8 x 3/8” pan head screw from the hardware sack kit.

Route control cable and insert end of cable into second hole from the pivot of the
crank arm

Attach using the #8 screw.

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CAUTION: The control cables are equipped with inline adjusters. Adjust the
Defrost, Heat/ Face door to its full travel. Make sure that the water valve com­pletely closes when the cable is in the cold position.

The Micro Switch that is mounted on the top of the unit is used to turn on the
compressor clutch. This will occur when the control knob is in the face position.
It may be necessary to adjust thin metal arm on the switch. Make sure that the
Clutch Micro Switch is depressed when lever is in the face position.

Locate the (5) terminal plug on the end of the wire harness for the unit. Plug this
into back of the blower switch.

Locate brown wire that was the power wire for the original heater. Cut off the
connector and attach (1) ¼” male spade connector.

Attach this wire to the red/white stripped wire from the unit wire harness.

Check the heater fuse and be sure that it is min. 25 amp.

Locate in the hardware sack kit (2) grommets.

Insert into the (2) holes previously drilled.

Locate the (2) pieces of heater hose from the unit box.

Insert hoses through grommets from engine side of the firewall.

ENGINE SIDE OF FIREWALL

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Located behind the glove box opening.

Attach the two hoses to the heater connections on the unit using (2) worm gear
clamps provided.

Tighten securely.

Locate the liquid hose (smallest), suction hose (largest), and (2) bulkhead plates
from the hardware sack kit.

Insert bulkhead fittings through (1) the bulkhead plate and then through the
firewall.

On engine side of the firewall attach second bulkhead plate over the fittings and
use the fitting nut and rubber seal to attach. Tighten securely.

Route smallest hose up and around blower and attach to the expansion valve
using (1) #6 o-ring and a few drops of mineral oil.

Route largest of the hoses around blower and attach to the unit using (1) #10
o-ring and a few drops of mineral oil.

LIQUID HOSE

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Locate the refrigerant insulation tape from the hardware sack kit.

Wrap metal connection using the tape. There should be no exposed metal surfaces.

Locate the clear ½” drain tube from the hardware sack kit.

Attach over drain nipple on bottom of the unit and insert other end through the hole previ­ously drilled.

Reinstall the radio.

Locate the center dual louver assembly, (2)
#10 x ¾” tek screws, and (2) #8 x 3/8” pan head screws.

Attach hose adapter to bottom of the dash using #10 screws. Be sure to center the louvers
under the radio.

Attach front louver assembly to the hose adaptor using the #8 screws.

Locate 2”flex hose from the unit box.

Cut (1) piece 18” long and (1) piece 20” long.

Attach 20” piece to driver’s side louver and 18” piece to the passenger side.

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Locate the single under dash louver assembly, and (2) #10 x ¾” tek screws.

Attach the housing to drivers side under the dash using #10 screws.

Insert louver into the housing.

Locate 2” x 36” and 2” x 24” (2) flex duct. Cut one piece at 32”, one at 20” and
one at 18”.

Attach 32” hose to the driver’s louver and route across to left outlet on the unit.

Route 18” flex hose from center louver to next left outlet on the evaporator

The 20” flex duct goes to next outlet on the evaporator.

Locate the single under dash louver and (2) #10 x ¾” tek screws.

Attach housing to driver’s side under the dash using the #10 screws.

Insert the louver into the housing.

Locate last of 2” x 24” flex hose and cut 23” piece. Attach flex hose to hose
adapter on back of the louver. Route hose up and behind glove box opening.
Attach to last remaining outlet on the main unit.

32” 18” 20”

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The engine compartment components should be installed at this time. Carefully
follow the electrical diagram provided on page 8.

COMPRESSOR MOUNTING COMPONENTS WILL DIFFER DEPENDING ON
ENGINE AND DRIVE ACCESSORIES THAT YOUR VEHICLE IS EQUIPPED WITH.
THE FOLLOWING INSTRUCTIONS SHOW THE PROPER INSTALLATION
SEQUENCE FOR THIS VEHICLE

Locate the following components from the under hood components box:
Condenser
Discharge Tube
Liquid Tube
(4) Condenser mounting brackets
(8) #10 x 3/8 hex washer head screws

Remove Radiator Fan, Shroud and the Radiator. Retain the original mounting
hardware.

Locate the drivers side radiator support Template from last few pages of the instal­lation instructions.

Locate template on the radiator support and drill (1) hole 7/8” diameter.

Locate the passengers side radiator support Template from last few pages of the
installation instructions.

Locate template on the radiator support and drill (1) hole 3/4” diameter.

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Locate the Liquid Tube from the condenser kit.

From engine side of radiator support insert the bulkhead through the ¾” hole previously
drilled.

The tube will lay between the grille and radiator support and will drop over into the
engine side as shown.

Locate the Discharge tube from the condenser kit.

Insert bulkhead end of the tube through the 7/8” hole on drivers side previously drilled.

Locate condenser and (1) left, (1) right mounting bracket, and (4)
#10 x 3/8” hex head screws.

Attach both of the brackets to condenser in the 5th hole from the bottom.

GRILLE &

RADIATOR

ENGINE SIDE

SMALL FITTING

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Slide condenser assembly so that condenser is on engine side of
the radiator support with the mounting brackets between the
support and the grille.

Note: Condenser top edge should be even with top
of the radiator support.

Attach tube assemblies to the condenser fittings using o-rings
and a few drops of mineral oil for each connection.

Locate (2) #14 x ¾” tek screws.

Install lower condenser mounting brackets to radiator support
using the #14 screws as shown.

Locate remaining condenser mounting brackets, (4) #10 x 3/8”
hex head screws, and (2) #14 x ¾ tek screws.

Attach brackets to condenser using #10 screws and bracket to
the radiator support using the #14 screws.

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Reinstall radiator, fan shroud and fan using the original hardware.

Note: It will be necessary to trim the fan shroud around the compressor clutch.

Locate the discharge hose and (2) #8 o-rings.

Attach end with service port to the compressor using (1) #8 o-ring and a few drops of
mineral oil.

Other end attaches to #8 bulkhead fitting on the radiator support using (1) #8 o-ring and a
few drops of mineral oil. Tighten securely.

Locate the #10 suction hose.

Attach end of hose with the service port to the compressor using (1) #10 o-ring and a few
drops of mineral oil.

Route suction hose from compressor to #10 fitting at the firewall.

Attach to the fitting using (1) #10 o-ring and few drops of mineral oil.

Locate (1) hose clamp, and (1) #10 x 3/4” tek screw from the condenser kit.

Attach suction hose to firewall using the clamp and screw.

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Locate the Receiver / Drier, hi/low pressure switch, Drier Mounting bracket, and (2)
#10 x ¾” tek screws.

Attach pressure switch to the drier and then the assembly to inner fender liner behind
battery box
using the (2) # 10 x ¾” tek screws.

Locate the short #6 liquid hose and (2) #6 o-rings.

Attach hose to bulkhead fitting from the condenser tube. Route hose up in front of
battery and attach to inlet on the drier using (1) #6 o-ring and a few drops of mineral
oil.

Tighten all fittings securely.

Locate remaining #6 liquid hose assembly and (2) #6 o-rings.

Attach 90 deg end to drier and route hose along fender well and the 45 deg end to
bulkhead fitting on the firewall.

Use the (2) #6 o-ring and a few drops of mineral oil.

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NOTE: THE SUPPLY LINE FROM THE ENGINE WILL BE HOOKED TO
THE DRIVERS SIDE HOSE.

Locate in the Hardware Sack Kit the Water Valve and (4) worm gear
clamps.

Attach the water valve to the passenger side hose. Use the worm gear
clamps supplied.

Cut the supply hose from the engine and attach it to the hose splice on
the drivers side heater hose. Use the worm gear clamps supplied.

Locate the Temperature Control Cable and attach it to the water valve
as shown. Set the cable so that the Temp knob is pushed all the way in
and the water valve is in its fully closed position.
Locate the electrical plug that attaches to the Pressure switch on the
drier

There are two white wires attached to the pressure switch, route one of
them to the compressor clutch and attach a Female bullet connector.
The other wire route along the Liquid hose and attach
to clutch wire at the firewall. Secure wires with tywraps provided.

Use the same refrigeration tape to seal around the cable and clutch
wire.

Reinstall and reconnect the battery.

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THE ENGINE COMPARTMENT OF YOUR SYSTEM IS COMPLETE.

THE UNIT IS READY FOR EVACUATION AND CHARGING.

THIS SHOULD BE DONE BY A QUALIFIED AND CERTIFIED AIR CONDITIONING

TECHNICIAN.

NOTE: COMPRESSOR IS SUPPLIED WITH THE

CORRECT OIL CHARGE. DO NOT ADD OIL TO

SYSTEM.

134a SYSTEMS 24 oz OF REFRIGERANT

Recommend that power fuse is 25amp minimum

Congratulations you have completed the install of your CLASSIC AUTO AIR “Perfect Fit Series” system.

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IMPORTANT!

CAUTION: WATER VALVE MUST BE INSTALLED PER THE INSTRUCTIONS.

This data sheet covers the proper instalation of the “Temperature Control Water Valve” that is supplied in your Air Condioning , Heating, and
Defrost unit. Classic Auto Air has done extensive testing on the correct method to install the water valve in order to get a repeatable and
progressive temperature control.

It is necessary to locate the “Supply Line” from the engine on the vehicle and route a hose directly to the heater connection.
NOTE: The supply line will be coming from the engine block after the water has passed through and absorbed heat from the engine. Typically
it is located next to the return radiator hose from the engine to the top of the radiator.

Locate the “Return Line” from the heater connection. Cut 6” of 5/8” dia. heater hose and attach it to the inlet side of the water valve. Attach
this assembly to the return heater connection. Attach a heater hose from the outlet side of the water valve and route to the return
connection on engine. NOTE: The return connection is typically located on the water pump.

CAUTION: WATER VALVE MUST BE INSTALLED ON HEATER LINE ROUTED TO WATER PUMP.

NOTE: COMPRESSOR PURCHASED WITH KIT IS

SUPPLIED WITH THE CORRECT OIL CHARGE. DO

NOT ADD OIL TO SYSTEM.

134A SYSTEMS 24 oz OF REFRIGERANT

Recommend that power fuse is 25amp minimum

TDS-001 WATERVALVE

DRILL (2)

1 ” DIA

TEMPL ATE FIREWALL

DRILL 11/16 ” DIA

1/4