I had a leaking AC evaporator core and contemplated having it repaired at the dealer but the $650 repair price sort of got me thinking, which can be dangerous.

 

Anyway, I started to read up on the subject to see what I was up against (Thanks to Ferret & others). I figured if nothing else, if I fail I can still pay someone to get the job done. First things first, where to get the evaporator? I checked both local Subaru dealers and they were asking $350 & $400 respectively and online for $255 from SubaruParts.com. For a used one, I could find them from $35 to $350. Now here's where my thinking can get me in to trouble, but logic prevailed. My Forester is a 2003 model and so I figured if I got a used one off a junked newer model it should still have serviceable life, right? Anyhow, I went with the used (2005 model) $35 one and with shipping it cost $50 delivered. And to my surprise, it came with the expansion valve (which I also used because it looked cleaner than my original) and pipes attached and it was in great shape (had a little debris, leaves etc that I blew off with air compressor). With the replacement evaporator in hand, I proceeded to gather a few more things: o-rings, new drier, two cans of flush, PAG oil, two cans of 134A freon, a manifold gauge set & an electric vacuum pump. Now here's where I lucked out, my brother-in-law had the manifold gauge set that he bought from Harbor Freight for $45 but he had never used and he had one of those cheap venturi type vacuum pumps. With everything I read, you cant get enough vacuum from one to boil the moisture off. I called a couple tool rental places and two local Autozone's to try and rent an electric model but to no avail before I scored. The third Autozone (pays to live in a bigger city) had two rental units. The basic cost was $200 for deposit and a total refund when you return the pump (I for one will be buying more stuff from them in the future). Long story short, flushed the new (used) evaporator and condenser, then installed everything and ran a vacuum and to my delight, no leaks. Recharged and running cool! Repair time approximately 3 hours. Total cost $128 and piece of mind knowing the job was done right, priceless!

 

I love it when a plan comes together...

it saves SO much money when you can turn your own wrenches.

yeah i def. second aircraftengineer on that........just curious did you have to remove your whole dash to get the evaporator out?

yeah i def. second aircraftengineer on that........just curious did you have to remove your whole dash to get the evaporator out?

 

Negative! That's why I love Subaru's, they know how to design them to be repaired. All I had to do is remove the glove box & unbolt the blower assy (3-4 bolts) and pull the evaporator cover on the side and disconnect the plumbing to pull out. Piece of cake!

yeah i def. second aircraftengineer on that........just curious did you have to remove your whole dash to get the evaporator out?

It should be in front ot the radiator.

no the condenser is in front of the radiator.........

 

 

thats amazing....i always presumed that you would have to pull the dash to replace the evaporator.....thanks for the info.....

thats amazing....i always presumed that you would have to pull the dash to replace the evaporator.....thanks for the info.....

 

That's what I thought before I started the project.

disconnecting the pipes under the hood the lower smaller nut does it turn counterclockwise to loosen? It seems like it's getting tighter to me.

well crack this post is old but how did you track down this leak in the evaporator if you see this thread again?

 

i have no recollection of those nuts turning any differently than normal CCW, so that should be right. but it's been awhile since i removed one.