A/C system overhaul?

[apenland01]

I have searched the entire AC section, but haven't found anything I can sink my teeth into.

2005 EB V8 with dual cooling class 3 towing. About a year ago, occassionally, we started noticing a very short (less than one second) growl when we first started the vehicle, which it had never done. We could never reproduce the problem for a tech and over the last 6-8 months, the A/C takes forever to get cold.

I took it in for service and they found it was low on freon and there was leak in the manifold line. They also said the fan clutch was very weak, although we never had engine cooling problems since living in Arizona. We had the manifold lines and fan clutch replaced, along with normal A/C service.

Everything was good for a few days and then we noticed the air wasn't as cold anymore and that it started taking longer to get cold again. We are about a month out from all that service and my wife calls today to say the engine is making strange noises and that only hot air is coming out of the vents. She said temp gauge was normal, but there was a burnt smell.

The mechanic says the compressor is now locked up and the entire A/C system needs an overhaul to the tune of $1200. Is this reasonable and realistic, or is there a less expensive solution?

Thanks in advance for any replies.

 

[ranger7ltr]

This is not a good prospect...

If the fan clutch was weak the engine and a/c system may not have shown that they were running hotter than usual but they would be and not as much heat was being removed from the radiator and a/c condensor...Plus running low on refrigerant would cause the system to run hotter as well...

Now that the compressor is locked up there needs to be a determination what damage has been done...As the compressor runs hot, the teflon seals inside the compressor can melt then flow throughout the system...This stuff coats everything and it is called "black death" ...This problem necessitates a firewall-forward replacement of condensor, compressor, orifice tube, hoses, and accumulator...Usually the evaporator is not affected by melted teflon since it is on the cold side of the refrigerant system...

Having a tech repair this type of problem can easily run into the thousands...Plus you have the task of vacuuming the air out of the system after component replacement, replacement of refrigerant oil when components are replaced and finally installation of new refrigerant after the system is repaired and vacuumed dry...

Some Ford shops have access to tools that they claim can flush the teflon that is melted out of the system but the time involved to flush repeatedly vs. replacement of the components cost can be lower to simply replace the components...

Did the shop give you an estimate on what needs to be done? Did they pull the orifice tube and see a melted black goo on it? That deposit on the orifice tube guarantees that stuff flowed throughout the system... If the orifice tube is clean or only has a little loose particulate on it, perhaps a system flush and compressor replacement is all that is needed.. Link to the problems related to black death...http://www.ackits.com/merchant.mvc?Screen=CTGY&Store_Code=01&Category_Code=BlackDeath

Are you able to do any of the work yourself or have a friend help you?

 

[apenland01]

Service

Ranger7ltr,

Thanks for the awesome response!

The tech said when they checked the orifice tube there was large debris and residue, which he said indicated the whole A/C system should be replaced. I didn't understand why, but I certainly do now.

The tech said that all A/C equipment under the hood would be replaced, including compressor, condensor, orifice tube, all hoses, accumulator and any other parts required to replace the system. The quote was for $1293 using a remanufactured compressor and all the other parts being new. He said the warranty was the same for the remanufactured or new compressor and that it would save money.

Unfortunately, I don't have the tools or the time to do the repairs myself, I simply needed to understand why all of those parts needed to be replaced.

Thanks for the link and the info, it helps me justify spending that kind of cash for repairs..........

 

[Carguy3J]

Ranger7ltr,

Thanks for the awesome response!

The tech said when they checked the orifice tube there was large debris and residue, which he said indicated the whole A/C system should be replaced. I didn't understand why, but I certainly do now.

The tech said that all A/C equipment under the hood would be replaced, including compressor, condensor, orifice tube, all hoses, accumulator and any other parts required to replace the system. The quote was for $1293 using a remanufactured compressor and all the other parts being new. He said the warranty was the same for the remanufactured or new compressor and that it would save money.

Unfortunately, I don't have the tools or the time to do the repairs myself, I simply needed to understand why all of those parts needed to be replaced.

Thanks for the link and the info, it helps me justify spending that kind of cash for repairs..........

Other than pulling vacum and refilling the system, no "special" tools are required. It's just a few common hand tools.
In any event, that amount sounds rediculously high. I know the compressor isn't going to be cheap, but that's just way too much. I would get an estimate at an independent shop, using aftermarket parts. I'm also not sure you have to replace the condensor. You ought to be able to flush it out pretty easily, especially if it's already off the vehicle.

Still, if you're in NJ, I can fix it, replacing all the same parts, for a LOT less.

 

[apenland01]

Compressor failed again.........

ARRGGGHHHH!!!!!!!!!!!!

Today, the compressor failed again and a metal grinding sound. After spending $1300 only 2 years ago, I can't believe this crap is happening all over!!

Ford now quoting $2,100 for complete system replacement.

What in the world is causing the compressor to fail and completely contaminate the whole system???