My wife drives an 03 Expy XLT and we took it for a trip this past weekend.

After driving for a couple of hours w/ the A/C going (hot down here in TX!!), I suddenly felt the air coming from the vents decrease to almost nothing. I have the fan on 2, and the air was barely coming out of the vents. When I kicked the air up to 4, I could hear the fan speed up, but no increase in the amount of air coming from the vents.

I tried the A/C in the rear, and it was doing the same thing. I tried changing the temp, moving the switch to feet, defrost, etc., but nothing helped.

We stopped for about an hour to grab a bite to eat, and when we got back on the road, the A/C was working fine again. It continued working fine for the remainder of the trip (about an hour).

The same thing happened on our way back, and we had to stop and take a break. After about an hour, the A/C was working fine.

We have had no problems with the A/C during normal, around town driving.

Any ideas? I am trying to find out the cause before taking it in for warranty so that I can hopefully avoid the "can't duplicate the problem" crap that I've heard in the past.

Also, we noticed while on the trip, that obnoxious smell coming from the A/C vents, and it seemed to happen shortly before the air kicked down.

(Please note: I tried to do a search on this, and even read through the first 15 pages of this forum, but didn't see anything)....

Thanks in advance for any help...

 

There is a TSB on this problem. Search again.

 

Just tell your dealer it is freezing up on long trips and they will know what to do.