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I took my Expy to the dealer for some warranty stuff including an intermittent A/C problem driving long distances in hot weather. The air will stop blowing cold and I will have to shut down the A/C for about 5 minutes and then turn it back on.
I found the same problem on this forum, printed up the post and took it to my service rep. He confirmed the problem but informed me that this problem was not covered on my extended warranty.
I had an 03 with the same problem, Ford could not solve the problem as of Feb 04. I do not know if they ever figured out how to fix the problem. Ford gave me a new 04 as a direct replacement, the 04 a/c is still not wonderful but a lot better than the 03. I would not want to live anywhere warmer than Seattle with this poor performing/loud a/c system. I test drove an 07 and with the a/c on high it is a lot quieter than the 04.