Bought the D used. 2000 4.7 89K miles
AC not working.
I will summarize:
1.- Charged the AC with dye. It ran very cold for 1 day.
2.- Parked the vehicle. The drain water (condensation) has dye in it.
3.- I am sure the leak is at the evaporator core. Nowhere in the engine comparment can find dye.

I am up to the task to do the job myself. BUT if I can get tips that will make it easier please feel free to provide feedback.
Questions:
1.- Does any one knows of or has a write up on how to remove the dash (efficiently)?
2.- Does any one know of GOOD aftermarket evaporator cores for the durango?
3.- How about the heater core, do they normally fail in these vehicles?, should I replace it too?
4.- Any good aftermarket parts for the heater core?

I checked autozone, they carry the evaporator for 117.00, but my gut tells me to avoid buying it from them.
I would like to tackle this problem next weekend. Help is appreciated.
Thanks,
PESUAZO

http://www.dodgeforum.com/m_154314/tm.htm
i just replaced mine about a week ago. Going threw the dash is alot to deal with so be ready. Im not totaly certain its your evap core though. The evap core is a solid piece of metal and if it breaks you would have a sudden drop of your a/c freon. I would start by replacing the seals and gaskets around your expasion core. I had the same slow leak problem on my neon that i was never able to find until i took the expasion core off. Start small then work your way into the evap core. rockauto.com had a seal set for the durango for only a few bucks, i would start there or something close.

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'95 Neon Sport
'99 Dodge Durango SLT

Ive heard people suggest replacing the heater core once your in the dash. Myself, i would only suggest replacing a part that isnt broken if; routine maintance was not done on it (coolant flush), or it shows signs of possible failure. If you get into the habit of throwing parts at your truck your wallet is gonna feel some pain. You're also gonna throw long hours at stuff that might be broken.

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'95 Neon Sport
'99 Dodge Durango SLT

If you are pulling the dash:

- prepare for an all weekend+ job
- bag and label everything that comes off/out for reinstall
- replace the evap, fan blower and heater core all at the same time. You do NOT want to pull the dash a second time for one of those.
- factory parts are the way to go. Aftermarkets won't match up quite right and will need adapters
- parts will run $500 at the stealer
- jobber rate for install is $750, stealer rate for install $1500+ on all three items

HTH,

IndyDurango

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- Truck of the Month: 07/07 Dakota-Durango.com;
12/06 DodgeForum.com; 1/06 DurangoClub.com
- Durangoer of the Year: 2006 DurangoClub.com
- Three Time TotM Nominee: DTW.com

Don't be afraid to search for advice on the ram or dak boards too, these vehicles are all so similiar you'll probably get a good dose of advice from them too.

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Thanks for the feedback guys, it seems I am up for a big task removing the dash. I am definitely doing it, as I do not want to pay 750.00 just in labor. Crap, 750.00 is a 4 day 3 night stay at an all inclusive hotel in Dominican Republic (including airfare). That alone is motivation enough for me!!

Completed the job. I did a nice write up, about 5 MB PDF file (with pictures). Too big to upload.
E-mail me if anyone would like to have it.

A lot of responses requesting the write up. I have replied to all, but I have gotten some responses back (from the mail server) that the file is too large for the recipient.

Try posting it in a new thread in the DIY section, that might be your best bet. Great write up BTW.

Please send me this info. Thanks for the help.