Commander A/C Evaporator Core Replacement - Dash Out Job!

[Hanna]

My Commander's A/C has been playing up for over 6 months with it only spitting out cold air on the passenger side. With the mercury already starting to get close to 40C here, it is time to do something about it.

When I had some recent panel work done, they had to disconnect the rear A/C and re-gas after they were finished. After being told by the auto electrician that re-gassed it that it was my battery (which I replaced) and my alternator (which I replaced), I did my own research and everything points to the evaporator - which is full dash-out job...

I have ordered all new HVAC parts from RockAuto in the USA, including:

- FOUR SEASONS 54948 A/C Evaporator Core
- FOUR SEASONS 26782 A/C System Valve Core and Cap Kit
- FOUR SEASONS 83270 A/C Receiver Drier / Accumulator
- FOUR SEASONS 39018 A/C Expansion Valve
- GPD 1321313 A/C System O-Rings, Seals, & Gasket Kits
- TYC 3247 A/C Condenser
- UAC RO0900B A/C Refrigerant Oil
- OSC 98022 Heater Core

Total cost of around $400 posted to Karratha, WA. Even with the current crappy exchange rate that is great value! Delivered in just over a week too.

I have watched a heap of videos and read a heap of threads on this job and I know I am in for a big one.... Renovator's thread was also very helpful:

http://www.ausjeepoffroad.com/forum/...=146223&page=3

Any words of wisdom that anyone would like to share before I dig into this thing?

[Clarky]

Have you checked its not a blend door failure?

https://www.jeepgarage.org/threads/0...repair.186314/

https://www.blenddoorrepair.com/

[ren0vator]

The OEM manual is spot on in removing the dash board
But no help at all when it comes to disassembling the HVAC unit
luckily it only goes together one way
(mine is a single door variety)

Got someone to help you lift the dash out?
Removing the shifter will make it easier if it's a solo adventure

Good luck and post some pics

[Hanna]

Originally Posted by Clarky

Have you checked its not a blend door failure?

https://www.jeepgarage.org/threads/0...repair.186314/

https://www.blenddoorrepair.com/

Yep - checked the blend doors and the actuators were both working fine with no broken parts.

When I had it re-gassed about a year ago the A/C guy reckoned it had a slow leak, but couldn't find it anywhere under the bonnet and thought it could be the evaporator. After replacing the battery and alternator and it was still the same, I spent a whole day researching online and everything kept pointing to a leaking evaporator.

I was really wishing I could avoid this job, but here goes!

[Hanna]

Originally Posted by ren0vator

The OEM manual is spot on in removing the dash board
But no help at all when it comes to disassembling the HVAC unit
luckily it only goes together one way
(mine is a single door variety)

Got someone to help you lift the dash out?
Removing the shifter will make it easier if it's a solo adventure

Good luck and post some pics

Shame I don't have a copy of the OEM manual for the commander!... Maybe I can find one online before starting?

I will be doing this solo and I was planning pull the shifter out anyway - most of the online videos show them removing it.

I will definitely take plenty of pics to help me get it back together. Posting them will depend how successful I am!!

[Hellcat]

Mine was cold only on the passenger side and it turned out there wasn't enough refrigerant in it. Unfortunately the AC guy had put the incorrect amount in during a regas (two charge weights for the commander, the larger being the one with the rear air) . He also failed to detect that there was a small leak on the valve stem on the low pressure side.

Been good ever since I got it regassed with a new valve in it again...

I was all set to tear the dash out as well... I watched this YouTube video for inspiration :

You Tube

I personally wouldn't attempt the job unless you're absolutely sure that's where your problem is.

[Hellcat]

I forgot to ask, do you know if the Ac system held a vacuum when they evacuated it?