2003 durango AC Problems

[Nick Bailey]

I have a 2003 Durango SLT Plus 5.9 Lt with many of the same AC problems as everyone else. What I need is some step by step advice based on the information I have listed below.
LOCATION PROBLEMS
1. I am currently living in Qatar and the cost of parts and dealer work is very expensive. For instance a new AC compressor is about $1300 US fitted.
2. I can get some parts there, like relays etc. which aren’t too expensive otherwise I have to order through E-Bay which takes about 10 days.
3. Non – Dealer mechanics who know about these cars are few and far between and if anything is too hard they just leave it.
4. The temps here are on average 102 – 115 for 6 months of the year
AC PROBLEMS
1. The air is just not very cold in either the front nor the back
2. The air will only blow from the dash vents, I have no windscreen or feet in any combination, on either recirculated air or outside air.
3. It sounds as though there is a small hurricane in the dash in relation to the air volume coming from the vents.
4. I have no heat, (this is not a real issue, just thought I should mention it)
NOTES
1. I have replaced the AC Compressor & Dryer
2. I have replaced the Clutch Fan & Thermatic Fan & Relay
3. I have wrapped the lines in Neoprene and heat shield tape.
4. I have had the gas checked again and again.
5. When I change the air from recirculated to outside air, there is a noticeable change in the air volume and also the noise of the fan. I also noticed that if I change to outside air a lot of dust comes into the car. This indicates to me that the door for this is working.
QUESTIONS
1. What else can I check and replace without pulling the dash down, ie; relay’s – expansion valves – fuses etc?
2. I have heard that the heater core feeds are very close to the plastic air ducts, and can cause them to heat up. Does blocking the heater core feed help?
3. Is there only one blend door or are there a number for the various settings, ie; windscreen, feet, face?
4. How likely is it that the evaporator core is the problem.
5. What is the basic problem with the system? Is it the size of the compressor? The size of the Evaporator core? The size of the ac radiator? or combinations.
Anyway I hope someone can help me with this as I currently can’t drive or sell the vehicle, summer is just starting so the vehicle will just sit until xmas.