Ok, here's my plan, please tell me if I'm on the right track:
1) manually "flush" compressor with PAG-46 oil ($7.70) keeping track of the amt of oil that goes in and out.
2) add ~2oz oil to new accumulator/drier ($23.24) and oil to compressor. Entire system should have 7 oz oil in it.
3) Should I flush the evaporator and condensor? How can I tell how much oil is in them?
4) inspect and clean outside of evaporator with some household cleaners to prevent odor
5) replace broken hose, accumulator/drier, orifice tube ($0.86), and any o-rings I run into ($8.34) lubricated with Nylog Blue ($6.90).
6) evacuate system with 1.5 CFM vacuum ($99.50). What's the difference between 1-stage and 2-stage?
7) Recharge system. Do I need a 2-gauge-3-hose manifold, or can I make due with something less. This would be another ~$100.
List Looks good.
Get the manifold here:
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=92649
They cost a bit less in the store if there is one around you. We have one in Albany.
They also have a 1.2 CFM version of the pump at harbor freight for $69 bucks, but the link I gave you will give you great support on the pump. They are a local company in Newburgh, NY.
The cheaper compressor pumps aren't the greatest since they don't have the capacity to pull a strong vacuum. Also, they will overwork the compressor. I strongly suggest not getting that. If you are on a budget get the one from HF.
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=98074
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=98076
You should pull vac for a good 2-3 hours.
Flushing is not necessary unless you have an exploded compressor. You will often leave flush residue in the system. Also, flushing a condenser is usually futile because of the design. If the compressor explodes it is just replaced. A/C kits would not advise a flush unless you had a catastrophic compressor failure.
If you replace the accumulator, drill holes in the old one and see how much comes out. I would add 6 oz of oil to the system in your case(taking into account the compressor). There was a TSB that its ok to add a few oz more of oil to the explorer(2 or 3 I think). I had an evaporator crack and there was barely any oil in the system. Nice oil puddle under it though. Each item you replace (hose, orifice, accum) is approx 2oz according to the manual.
NYLOG blue is for R134a systems, and is superior to using oil. Make sure to use a healthy amount on both the o-rings and the area on the fitting between and beyond the outer 0 ring. This is how the outer 0 ring is kept pliable. For the orifice you can use oil, because it comes with the orings on the body. you want to dip it in the oil so it seeps under the orings.
The evaporator teardown is an optional step. If you do that REPLACE YOUR BLEND DOOR. It is definately accessible at this point. The part cost a few bucks at napa or advance. You can wiggle it out from the Evap opening. Search the site for the part number. Doing that may be worth the trouble. (not sure if its a problem for 99s though), maybe someone else can chime in.
If you want to know more about the pumps, call classic tool design(I posted it in the first post). He will explain everything to you.
You will also need a spring lock removal tool. If you are creative you can make one out of a motor oil bottle cap or safety seal. Just cut a strip that matches the circumference of the fitting, and slip it into the spring lock coupling, trying to displace the garter spring. Then slide the fittings apart.
The garter springs can be replaced too, you can get them at napa or from ackits.