Jeepwalker

I was looking at older XJ's at the time so not sure if this would fit yours:

https://www.ebay.com/itm/1997-1998-1...wZYRy4JtW4n7RQ

I bought mine on ebay too. I wish some of the Jeep suppliers would get on board selling the copper heater cores.
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Furrydogs

NCDON, when you took the HVAC box out and when you put it back in will you have the whole HVAC assembled or will you put the two pieces together once you get it in the cab? I've only partially detached the dash so I don't know if I can fit the whole thing in one piece. The last time I did it in two pieces, wasn't very easy but I got it together

By the way, my first heater core was bad, it leaked where the pipe meets the core:

Ralph77

I am wondering if that is what Superior Cooling is selling at their site.

NCDON

"NCDON, when you took the HVAC box out and when you put it back in will you have the whole HVAC assembled or will you put the two pieces together once you get it in the cab? I've only partially detached the dash so I don't know if I can fit the whole thing in one piece. The last time I did it in two pieces, wasn't very easy but I got it together

By the way, my first heater core was bad, it leaked where the pipe meets the core: "

Reply:
I removed the box assembled from the cab and disassembled on the workbench. To get a little more room I did remove the drivers side AC vent cover, this allows the dash to swing just a little further out from the firewall.

I'm still waiting for the brass/copper heater core to arrive to finish my job......

NCDON

I picked up the new heater core from the radiator shop yesterday, the core is brass/copper and looks just like the core sold at Superior Cooling that is mentioned in post #16. The core I received is a little larger without measurement I will guess 15% thicker and slightly longer then the factory core. The extra length made for a very tight fit in the heater box space so I removed a plastic insert that is in the 1999 XJ, not sure what years would or wouldn't have this insert. The part is not shown in the FSM and doesn't appear to be anything but a spacer to prevent core movement.

Put the heater box and dash back in the jeep and started up without issue. Took a drive, checked for leaks and drove around for 10-15 minutes with a pyrometer probe in my floor register, outside temp was 55F, temp out of floor registers a toasty 147F.

I estimate I have 9-10 hours in this job and found it to be much easier and a whole lot cleaner then other repairs I have completed, think replacing a pan gasket on a non lifted XJ and changing the rear seal. If I had to do the job again I would investigate completely removing the dash from the vehicle, this would give so much more room to work making the heater box easier to remove and reline at installation.

For now, all is good. I will update if this core gives me any problems.