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Disassembled the AC....
First discovery: the intermittent dash vents were caused by the disintegration of the plastic top end of the air door shaft that fits into the plastic arm that attaches to the vacuum servo. Cure: make new end with JB Weld.
Second discovery: the evaporator leaks were caused by corrosion where the ends of the evaporator lay against foam padding which holds moisture against the aluminum coils. Cure: Epoxy coat the ends of the new evaporator, and replace the foam with a bead of silicone seal.
Third discovery: the evaporator coil was almost totally clogged with crud and grime: Cure: develop a way to mount a pre-filter for the AC/Heat unit. Any suggestions?
Results: time will tell
Note: I didn't notice any difference in quality between the OEM evaporator and the aftermarket replacement. I believe the problem with Dodge evaporators is caused by their method of mounting, not by inferior evaporator quality.
One more thing: the use of Super Seal was a waste of time and money.
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http://morningglory.homestead.com/morningglory/web1.html
Married 37 yrs, 2 kids, 3 grandkids, 3 horses, 8 dogs, 2 cats, 05 URAL Patrol, and oh yeah, the truck: 03 3500 4WD SLT HO 48RE, AFE, Banks boxes, DiPricols,RhinoLiner, Hadley Ambassadors, 03 Laramie grille, custom leather. Jesus saves!
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