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I had bout forgot about this thread. LOL. I've been tinkering around with mine. I put the blower motor out of my parts truck in it. That helped a little. I took it back out and tried to wash the evaporator coils out with my water hose the best I could. That helped some too. But the biggest problem I found and fixed is the plastic housing under the hood that holds the A/C system is a two piece affair. Mine was split apart at the seem slightly and blowing cold air into the engine bay. I sealed it back up the best I could with some black rtv silicone. That helped some too. Turn your A/C on and run your hand around the housing at the seem, if it's leaking you should feel the cold air coming out under the hood. I am still looking for a better blower motor as I'm still not getting near the airflow out the vents my 96 has. I just don't have much time to mess with it here lately.
They are dicussing this same issue on the big bronco forum. Greystreak has suggested useing the squirell cage from a newer year car/truck. It seems that they have made advancements in the fan design.
I worked on my ac today having little success with air flow. I came up with a last resort before piling my dash. I removed the trim bezel, plugged up all but the second vent from the drivers window. Through this port I inserted a 5gal vacume hose that I had hooked to the output so it would blow. I inserted the hose and routed it toward the third port then down just before the opening then blocked everything off as air tight as possible. I ran the vacume, blowing, for 15 minutes. Turned it off to cool then repeated this procedure several times throughout the day. It actually helped. I believe if I repeat this a couple more days I might alleviate my problem. This is not a perfect fix but it seems to work!!
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.