Complete AC system replacement. Basically everything other than the hard lines, which were thoroughly flushed. Huge thanks to
@flintknapper for advising and encouraging me throughout the process. Without his knowledge and help, I don't think I would have done this on my own. He is an incredible resource here on 'Mud and has helped many people with AC problems.
Compressor seized about 3 months ago and when that happens, tens of thousands of little metal shavings/particles are spread throughout the entire system, clogging and contaminating everything. On a 2003 LX, the AC system is even more complicated because of the rear air, so in addition to the compressor and condenser, you need to replace both front and rear evaporators and expansion valves. With the system completely disassembled, I used at least 3 gallons of AC flush to clear the lines. I kept flushing until I saw no residue or metal particles on a clean white cloth. This part was pretty time consuming but very important.
Reassembled everything and replaced every O ring I could see/reach. Nylog blue, which is a key sealer on AC systems, went on everything. After reassembly, I pulled a vacuum for 45 min, closed the manifold and held my breath. 1 hour passed and the needle did not move from 26 inches of mercury of vacuum (at 5000', you wont get to 29/30). That was a good sign. I ran the vacuum overnight to evaporate any moisture in the system and then charged it this morning with 3 12oz cans of R134a.
After charging the system, I was able to get a low of 41.9*F from the vent, with an outside ambient temperature of 100*. That is a pretty incredible number and now the AC in my Lx is ice cold. It was a good learning experience and while it took me a solid 20 hours, I took my time and am satisfied knowing it was done right. There are a lot of corners that can be cut by a shop, only to cause problems down the road.
As a bonus, I noticed my heater Ts were looking pretty bad so they got replaced. They were very brittle and practically disintegrated upon removal. No large pieces went down the hoses but I'm sure a few small ones entered. No big deal as I am going to replace the radiator and flush the system (switching to standard green coolant) when I do the timing belt/water pump this fall. After the AC job, the T belt/water pump should be EASY. Also did an oil change since I was in wrench mode.
Just a fraction of the mess in my garage but some of the key components that were replaced.
Charging the system. A quality vacuum pump and manifold gauge set are key. HF stuff is to be avoided at all costs here.
My reward for a few long days of wrenching. AC has never been this cold and is now downright FRIGID, even with an ambient outside temperature of 100*F.
Heater Ts. These were bad and did not look like this a few months ago. I got lucky here.
Truck is now ready for hunting season! Which starts next Thurdsay with antelope.