1995 Windstar Evap changeout

Need some advice here.

I've got a 1995 Windstar and I've had it for about 6 years. About a month after I purchased it, I noticed the air getting warmer. After taking it to the mechanic, they told me the evap was leaking and it would be $1400 to fix. I laughed, paid him his $35 and left. Freon is much cheaper and while maybe not the environmentally responsible fix, it was certainly easy on my pocket book. Since then, I've always charged it in the late spring and had to put in around 1 pound near the end of the summer. This cycle has always worked and let me know that the leak wasn't too bad. This year, things changed.

Last weekend, I charged it because we were going camping and I use it as my "MAN-VAN" to tow my camper or boat. It worked great that weekend, but when I drove it the following Tuesday, the A/C was warm again. The leak has increased so now I think I need to address the problem.

I looked on RockAuto.com and I can procure an evaporator for $60. My question is, has anyone ever swapped just the evap and if so, how difficult was it? How do you extract it from the plastic case?

Just looking to get my Man-Van back up and blowing. I have some fishing/camping to do this summer and I need to travel in style. (note the sarcasm)

The $1400 quote was because it is a job that has a standard repair time of 6.3 hours....not including evacuating and recharging the A/C.
Also, FORD updated the unit........so the dealership part has a list price of $499.98.....as you have to get the whole box with heater core and evaporator due to the design change of the part.

Mine failed.......and I had the work done for me......because it is a reall pain in the rear to do......up under the dashboard.
Also......it is illegal to do A/C work on your own in Wisconsin......you have to have a license to buy the R-134.
They were able to get a aftermarket core that matched the OEM unit that was in my vehicle.....which is what I am guessing you are looking at on Rockauto.
That may actually add some more labor to the job.....taking apart the box and changing the evaporator.........But I don't know for sure.
The repair to mine worked just great....and still works years later

The instructions tell you to remove the instrument panel to get to the box.
It looks like the box comes apart at about the heater core location.
You have to remove the heater core from the box to get to the evaporator core.
They state that you also have to replace the accumulator (engine compartment) when you do this job because the A/C system has been opened up.
You will need to evacuate the system and add new refrigerant.


If you do work on your vehicle.....you may find a subscription to Alldatadiy to be worthwhile....they also keep updating your vehicle information with TSBs as they are released by FORD.
You might be able to find FREE information on the AutoZone website as well.

Wiswind,

Thanks for the reply. I do actually have an Alldata subscription (which I agree is priceless). My problem is that I have both a 2000 and a 1995 Windstar. For most purposes, my 2000 subscription has done fine. My 1995 is a backup vehicle so I rarely have to do much work on it.

Is your subscription for the 1995? The reason that I ask is because my 2000 subscription says that the evap can't be replaced as a unit. Is that the same on the 1995 model?

I don't mind doing the work (because I can take my time due to it being a backup car.) I can evacuate/replace the freon myself. It would probably be a pain, but it would thousands cheaper to do it myself. I'm just curious if the 1995 airbox can be opened.

Mark

The alldatay instructions for my '96, and I am guessing the '95 will be pretty much, if not exactly, the same.
They show the box can be taken apart....and state that the evaporator housing is to be replaced.......which I think is because of the redesigned unit.
My shop got an aftermarket core that was the original, old style.......and avoided the cost of the housing unit ($128 instead of nearly $500).
They don't have the best diagram.....and say that the heater core needs to be removed to get to the evap coil.......which is above it.
The ducting section connects to the "Heater Housing Core Plate" which is the part that is in between the ducting section and the evaporator housing.....
The evaporator housing looks to be the rest of the box......the largest part in there......the blower is mounted inside it......etc.

About the first step is to "remove the evaporator housing" which is likely the most difficult part of the job.
IF they sell just the evaporator core.....then there must be a way to replace just that part....but you will need to make sure that you are buying the one that fits the box that you have.

However.....I am just reading the alldata manual and remembering what my mechanic told me when he did mine.