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I have a 2002 Eddie Bauer expedition. The main ac blows warm air. The rear blows cold. At idle low side 37 high side 190 ambient temp 90 degrees. Small line on evaporator coming out of firewall sweating and cold large line warm. Could problem be a blend door?
Very likely. Also have an assistant cycle the temperature selector control from cold to hot and back and you watch the hot water valve linkage to make sure the hot water valve is cycling closed and open in conjunction with temperature selection. But if the back is getting cold and the front is stuck on hot, the front blend door actuator is a very likely suspect.
A blend door issue won't cause "Small line on evaporator coming out of firewall sweating and cold large line warm". The large line (output) is warm because there isn't enough refrigerant.
I failed to mention that while front vents register about 85 degrees while the rear are about 60. Shouldn't front vents get to 60 as well if it was due to low refrigerant. I agree that it's a bit low though. Where is the front blend door actuator located?
If the refrigeration system isn't functioning, the air coming out of the vents will be ambient plus a little. So, if it was 75 degrees when you checked outlet temps, that's about right. If it was 85 and the system was working just a bit, the temps would be about 80. It all depends.
Quit fixating on the blend door, get the refrigeration system working. If the blend door was malfunctioning, you' likely be complying about the outlet temps being stuck on HOT (like 100+ temps) or you'd have absolutely no control over outlet temps.
A blend door issue won't cause "Small line on evaporator coming out of firewall sweating and cold large line warm". The large line (output) is warm because there isn't enough refrigerant.
Just out of curiosity, how would a low refrigerant condition cause this? It's the condenser's job to cool hot refrigerant coming out of the compressor, so wouldn't a hot output line to the evaporator reflect more on airflow through the condenser?
He has a cold evaporator inlet but a warm outlet line from the evaporator. The condenser's lines were not under discussion. Since you mentioned it, it's the job of the condenser to condense the high pressure gas into a high pressure liquid, a process that removes heat from the refrigerant.
Within the evaporator, the opposite happens. The refrigerant essentially "boils" (evaporates) absorbing heat in the process. If there isn't enough refrigerant available to boil in the evaporator to utilize the whole core, only a proportionately lesser amount of heat will be absorbed from the cabin air passing through the core's fins.
Bottom line is that, in this person's case, there isn't enough liquid refrigerant entering the evaporator to absorb the amount of heat in the air passing through the evaporator's fins. That means either the overall level of refrigerant in the system is too low or, perhaps, the metering orifice is restricted (clogged).
Think of the system as a "BTU Transporter". It moves thermal energy (heat) from one point (the cabin) to another (outside).