The heater core in my 2001 TJ is again leaking, so last night I started to dig into it. The bad news is that I did this same replacement 7-8 years ago. The good news is that I documented it last time so had a great reference.
For those interested, here is the write-up I made in 2007 that Stu, from Stu-Offroad, graciously posted for me. To this day, I still get emails from folks who've used the write-up.
Here are some pics of last night's progress:
Tonight I plan to clean up the HVAC box of all the leaked residue, give the under-dash a thorough cleaning, and start throwing things back together.