2001 Econoline cargo van. 4.6L.

Just replaced entire AC system except blower motor and evaporator.

Here is what I have replaced:

Condenser coil,
receiver dryer
Compressor,
Manifold with hoses,
Resistor block
Blower motor switch
Ac Selector Switch

Also,
Water pump,
Radiator,
Fan clutch,
Thermostat.

But I'll be danged if the blower motor just doesnt seem to blow enough air!!!

It spins up fast, it is very torquey. But it won't blow from the dash to my face.

First time ford vehicle. Is this normal? If so, this is crazy. I find it hard to believe people would be happy with it.

 

From this sketchy worded description I'm guessing you don't know whether the blower motor is moving air through the venting system? Is this observed behavior new or just occur after all that work replacing parts etc?

Why were those parts replaced originally?

 

I don't know why you describe my post as sketchy...

This all started when I bought this van and it seemed ok, but it was winter. Summer came. AC did not keep up.
meh ok.

Well then while towing a light load, the van overheated. So I began looking into what we had.

The radiator was a single core! What? I am used to 4 core radiators. So I found that the 5.4l had the exact same radiator but 2 row. So I swapped it.

AC was still sluggish. So I replaced the fan clutch. I didnt even realize the old one was bad. The mew one definitely locks up and moves some air!

But while I had it all apart I went ahead and replaced the crusty water pump. And if you do the water pump, might as well get a new t stat.

Cooling issue seemed resolved.

Now back to AC.... I inspected the condenser coil and realized the fins were pretty well smashed up everywhere except where it was protected by trans cooler and power steering cooler. So I replaced it.
still not any better. So I keep looking. Well, whoever had it before me didn't maintain it.
I tore apart the AC and found the orifoce tube clogged with aluminum shavings.

Ok, replace everything. Compressor, hoses, receiver dryer. Because everything except the evaporator was exposed.

I used ac flush to clean all the dang green dye out from previous owner. If he had dye in it, there was surely a stop leak in it.

Still wasn't great. So I keep hunting. The fan blower speed selector was melted on the back at the connector. So I replaced the switch, the harness and the resistor pack. What I discovered was that the switch gets oxidized and dirty over time and resistance just builds up to the point of melting the harness connector.
The resistor pack seemed fine until I put my meter on it and found the thermal limiter was cracked. I didn't just replace it for no good reason.

I found the common vacuum reservoir issue causing air not to blow out of dash. Did the fix.

What I did notice this morning, which has been the first cooler day at 93⁰F that I have had. The nlower seems better. So I am thinking when it heats up it is slowing down. I will replace it now.

Just FYI, I am a licensed low voltage contractor and am also certifed universal HVACR 608 as well as automotive 609. So I am not just a diyer messing with ac components.

I own a refrigerant recovey machine, recovery tank, gauges, 6cfm vacuum pump and tools. It's not my first rodeo.

 

It’s not clear to me whether the issue is vent temp or air volume or both. Our ‘93 had good AC, our ‘07 has better AC, both vent temp and air volume. Not great in traffic which I’m sure a new fan clutch will solve. I’d rather fit an electric pusher but there’s no room.

If the blower is puffing but air isn’t hitting your face and you’ve sorted the vacuum reservoir, you might have a bad actuator. Most of the system can be checked through the access panel on top of the dash. Here’s a thread on a specific vacuum issue. I don’t think it’s what’s going on with your van but it describes where things can go wrong.

https://www.ford-trucks.com/forums/1...time-in-2.html

I can’t help a professional with vent temp.

Sixto
07 E350 5.4 198K miles