Automotive Air Conditioning Information Forum

IMHO, the advice Cusser posted is 100-percent correct.

If you have the knowledge, skills, and tools to work on the system yourself, I suggest concentrating on potential leakage points first. Leaks could be anywhere, but I would focus my attention on the condenser, the compressor shaft seal, the ...

The process you described earlier, plus the addition of Ease Release, sounds very promising. The only potential issue I can see is maintaining the PUR foam to a uniform thickness due to its expansion properties. I suggest doing a trial run on a disposable substrate first.

Let us know how it goes.

Option 1: I've never tried either option, but how about spray-on foam-in-a-can, the inexpensive type from your local home center that's designed specifically for sealing around windows? Unlike expanding foam that will fill gaps one inch or wider, the window variety features minimal to no expansion ...

Follow up:
A bit of research suggests that NyLog Blue would not be good for anti-corrosion protection on bolts?
Nylog Blue (NB) is formulated from a blend of very thick, extremely sticky refrigeration oils that hang on tight and don't harden. It's compatible with R-134a and R-1234yf (Nylog Red is ...

To ensure a leak-free system, I use Nylog Blue on every o-ring, threaded connection, Schrader valve, Schrader valve cap seals, etc. "A little dab will do ya."

So glad that you were finally able to remove the TXV--after days of work, I'm sure. Been there, done that...although not for this particular vehicle.

We're always interested in how our members solve MVAC problems, regardless of whether we have the same vehicle.

On to the next time consuming ...

That hose is strange looking, all right. It appears to be formed that way, but who knows? Dodge might have done that for clearance purposes.

What year is your van? Using the year, you could look-up the van's OE A/C parts and see what turns up (whether the replacement line is the same).

Cold Hose in Ocala, Florida, might be able to help you. They make lots of custom fittings and lines for MVAC systems.

Can you get in there with an oxy-acetylene torch (#1 tip or smaller) to heat-up the ends of the studs cherry red? If so, the nuts will come right off. Better wash off all the PB Blaster, though, and have a fire extinguisher ready.

As far as I can tell neither has been replaced. But they both look good and the fans seem to operate properly.
The fans could be "tired"—that is, not spinning at full speed. They should be operating with a noticeable roar. If not, I would replace them.

Also, check that all fan shrouds are in ...