I think I can answer all of your questions satisfactory since I have done several of these a/c installations. First of all if you check out your current truck underdash heater you will notice a short section of ducting between the heater and the blower motor/squirrel cage located on the far right? If you remove these ducting you can slide the a/c unit right in between the heater and the squirrel cage, the stock a/c hose holes are already punched through the firewall but are hidden behind the matting!
The stock a/c switch will have to be changed, but this is quite easy because the bottom part of the a/c-heater switch is the same as the non a/c, the a/c control part is attached to the top of the stock lower switch. This means you have to detach the stock heater cables, unplug the old switch, then install a heater-a/c switch back in its place. The wiring is the same as stock with the exception of a new "green" colored wire coming from the top a/c control part, this will be used to energize the a/c compressor. If you untape the factory wiring loom running across the back of the heater you will find a matching green factory wire already in the loom, same colored wire, just plug it in and the controlls are ready.
You will find this job much easier if you find a a/c Luv and take everying off of it, the compressor, brackets, lines,, all of it including the a/c radiator mounted in front of the stock radiator.
The a/c control switch will energize the green wire when the lever is moved all the way to the left (drivers side), There is a built in micro switch just behind the main switch. When the lever is moved all the way to the left, the green wire will send current through the factory wiring circuits all the way to the compressor!
After you mount all of the lines, brackets, you will notice a two prong low pressure switch mounted on the line running down the inside of the left front fender, again unwrap the factory wiring and you will find two green wires already wrapped inside of it, connect these to the new low pressure switch mentioned above. On the right side engine wiring loom you will find another green wire that will go to the newly mounted compressor.
I hope I haven't confused you but what I am trying to say is that this is a straight forward swap, the wiring is already in the stock looms, whether the truck had factory air or not.
If you have swapped out the stock engine for a sbc, the procedure is the same, it is just a matter of making up new lines to run from the stock a/c firewall connections to the new a/c compressor, dryer, etc. Please do not hesitate to ask for further explanation and I can e-mail some pictures if needed. contact me at
pinkertondusty@aol.com