How to change the thermal cutoff fuse on the 2003 Honda Pilot.

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How to change the thermal cutoff fuse on the 2003 Honda Pilot.

  1. 1. How to change the thermal cutoff fuse on the 2003 Honda Pilot. Step #1 Required Tools: 1. Soldering Iron 2. Solder 3. Pliers 4. Tweezers 5. Philips Screwdriver Required Parts: 1. Thermal Cutoff Fuse part # 447-XYP2BN109-RC available from http://www.mouser.com for $0.40/piece. Shipping was $6.79 The part has to meet these specs: 114C 2A/250VAC The TSB can be found here: http://www.hondapilot.org/forums/attachment.php? s=&postid=210593 Step #2 Remove the transistor part from the car and disassemble it.
  2. 2. Step #3 Remove the top plastic cover on the part, there is a small leg in the front that needs to be pushed in and the cover slides right out. Step #4 Now Remove the two screws on the outside as seen in the picture.
  3. 3. Step #5 Now you should be able to separate the heatsink and the transistor housing as seen in this picture. Step #6 Now you can desolder the old part and install the new one. Heat the solder as seen in the picture. As solder melts remove the part with a pair of tweezers.
  4. 4. Step #7 Here is a picture with the new part ready to install and after it was installed. Before you install the Heatsink it’s HIGHLY recommended to wipe the old heatsink grease and evenly distribute new one. I also covered the new part with grease (Grease available in most computer stores) Now trim the wires and reassemble the part then reinstall it into your car and enjoy your rear A/C again. If you want heat to blow out of the upper rear vents then hit the “MODE” button till it shows face arrow and then hit the “A/C” button so it says “A/C OFF” and adjust the temperature accordingly.
  5. 5. This is what mine looked like after I was done.

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