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Sounds lke the front AC vent is still open and is mixing with outside air. Look behind the glove box and make sure the vent is closing all the way. Also you could have some junk in the AC core up there. They make something that can be injected into it to clean it real good.
That might be normal. Ford seems to think that drivers are unimportant First, the front A/C is not as cold as the rear A/C. Then to add insult to injury, the air vent in front blows harder on the passenger's side than on the driver's side. At least, that's the case with both of my Aerostars
I would also add that a After market fan motor does not blow as hard as a factory Fan. I have no idea why but I have seen this many times. I think the after market fans have less windings or something cheap that makes it turm slower.
Sounds lke the front AC vent is still open and is mixing with outside air. Look behind the glove box and make sure the vent is closing all the way. Also you could have some junk in the AC core up there. They make something that can be injected into it to clean it real good.
Muffinman...I'll check out that vent. It is probably dirty. Nothing much on this vehicle got much TLC from previous owner. A/C core? Is that the evaporator you're talking about? (I should know this). When you say "junk in the A/C core"...you mean "literally" inside the tubing of the core? Hmmm. Sounds like I need a cooling system evacuation?
Copper...It figures that they would make the driver's cooling limited...maybe they figure that most drivers would make everyone else "sweat" and turn it off if they didn't design it that way?
Before you do anything to an A/C system that seems to be working, buy a temperature probe, stick it in the front and back vent, and tell us what the temperature readings are. If you get a 25-degree F (about 14 degrees C)drop from ambient air, I would say leave it alone. Also, remember that you have R-134a which doesn't work quite as well as R-12.
All kidding aside, I think the main reason the rear A/C seems colder is due to the rear tinted windows, which partially blocks out sunlight. Add that to the fact that the rear is always working in recirculation mode, and you can see why.
As far as the evaporator is concerned, I think it is more likely to have collected some junk like dead leaves, dirt, insects on the outside than to be plugged up inside. At worst, the screen on the orifice tube might be dirty, and in that case it would help to have the system evacuated and the orifice tube changed.
Don't forget that sometimes something can get stuck inside the ductwork and block the diverter. I had an ink pen that went down the defroster and blocked the diverter. Changing from hot to cold with the temp selector you cold fill the restriction.
I can't remember if it stuck open or closed now. I had to open the door to the heater core and the pen fell out. Problem fixed. Turn the temp control and see if it goes all the way to the cold position. Can't hurt to try.