96 XJ evaporator replacement help - fit up issue
 

I am replacing my ac evaporator due to a leak. I bought the replacement from four seasons (p/n 54812) and got the old one out with the help of the forum. However, the new evaporator is slightly taller by 3/8" and doesn't fit in the plastic evap box (the lid won't sit flush). Has anyone run into this and how did you get by? Also, if you have successfully retrofit the ac temperature probe (since there is no thru hole in the new evap), please comment on that too. Thanks in advance.

Wrong part..

That should be Chrysler part number 4773 117, which your Four Seasons part should fit.

The only thing I could think of is the part was not manufactured to spec.

Try to fit it again, see if you are missing something, if it still doesn't fit, exchange it for the GDP part instead.

Evaporator Coil part number 4773117 (now 4773117AC) is available from the dealer or on-line.


Bring some K-Y Jelly with you if you go to the dealer.


http://www.moparamerica.com/oe-mopar/4773117ac

Right number wrong part..http://www.autozone.com/cooling-heat...re/859255_0_0/

Hello,
I know this is an older thread but, as I'm looking to buy one of these now, I'll point out that several listings are using
both of the part numbers listed in this thread, 4773117 (now 4773117AC) and the OP: (p/n 54812).
Since I got the box out, I'm just going to wait to open it before I make a decision, just an FYI.
I'll try to update when I find the one that fits.

Andy.Raleigh

So I'm wondering if gundog every got that model to fit? I'm having troubles finding an exact replacement and many seem to have bad results/reviews. Has anyone got one of the new ones to work in a 96?
I was having trouble w/ the AC in the 96 I bought recently. Since I had to re-do the dash anyways, I pulled the HVAC box. This looks like culprit #1 - Other than the dirt the rest of the evap core looks good. Here you can see the one nozzle is bent pretty bad. Is this fixable?

https://cimg4.ibsrv.net/gimg/www.che...e28eab8754.jpg

Re: thermostat
 

Many thanks for the evaporator tip. Got the new one on the way. I got the old thermistor out using the method you described.
Just wondering how well the AC putty worked for you and if you could/would recommend the brand you used.

Thanks again,
Andy

Bent Evap Nozzles?
 

Got the new evaporator. Is it just me or is this thing messed up? Seems the nozzles are bent in on each other to much. Feels like I'd break it trying to install. Just looking for some feedback here as I 've never really worked on A/C before. Not sure how workable/pliable everything is.
I was thinking of returning this and getting another.
https://cimg6.ibsrv.net/gimg/www.che...77b8d21082.jpg
The left original one is bent pretty bad. The new one on the right looks to close together.

Any input on this would be helpful.
Many thanks,
Andy.Raleigh

OP here
 

I ended up using the evap that I had purchased. It didn’t fit the plastic box exactly as the OEM had, so I used a torch to “gently” heat the plastic and used the new evap to “gently” stretch/reform the bottom of the box just enough to work. I didn’t have misalignment issues with the plumbing. Also, I just stuck the probe thru a row of the softer fins in the middle of the evap. A/C is still going strong today several years later.
https://cimg0.ibsrv.net/gimg/www.che...10550c5cf.jpeg
https://cimg7.ibsrv.net/gimg/www.che...499d7f31b.jpeg
https://cimg8.ibsrv.net/gimg/www.che...9e0ef1dd2.jpeg
https://cimg2.ibsrv.net/gimg/www.che...7d6f5f6ae.jpeg
https://cimg4.ibsrv.net/gimg/www.che...4a0d73e34.jpeg

Wow, it might come that, many thanks! Gotta be extra careful with that plastic. I never thought of putting the thermistor in that way! - I might do along the side as I've seen before. Maybe I'll get lucky and found a replacement. Found someone selling what looked to be OEM but, we'll see when it gets here.....l