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Dual zone front/rear ac systems have 2 evaporator cores. And 2 orifice tubes, which are just inline filters. Either your front evaporator core or orifice tube is probably stopped up.
Sometimes you can get to the evaporator cores without removing them from the vehicle, and clean it. Evaporator cores do get stopped up sometimes, because the blower motor pulls in air with dust and debris from outside, and the air is cooled when it passes through the evaporator core.
But evaporator cores are a nightmare to replace, you usually have to remove lots of stuff under the dash and lots of stuff under the hood to remove them.
For a 2002 ford expedition the ac orfice tube is located in the evaporator core, remove the lower line to core and look inside , using a needle nose pliers pull tube out. heres a picture of the orfice tube, take note of which way the tube comes out and make sure the new one goes in in the same direction, good day.
the fixed orifice is located in the inlet tube to the evaporator core, this is where the small high pressure AC line from the compressor connects to the tube sticking out of the engine firewall, u will most likely need a special tool to remove it, here is a web link to the tool, don't damage the evaporator core by trying to remove the orifice tube without this if it is stuck down in the tube.
Did you change the Receiver/ Drier and the Orfice Tube/ Expansion Valve? The Receiver/ Drier takes moisture out of the system and the Orfice Tube/ Expansion Valve controls the Hot/ Cold air. If that is bad it may not be opening or closing fully which would not let your A/C get as cool as it supposed to.
It is located in the inlet tube to the AC evaporator core, the tube in deep inside that inlet, the small AC hose (called the liquid line) from the compreessor is what is connected to that inlet tube of the evaporator core, the evaporator core is what cools the air
SECTION 412-03: Air Conditioning
2001 Continental Workshop Manual
REMOVAL AND INSTALLATION
Removal NOTE: The evaporator core is serviced as a core and housing assembly. The evaporator core, internal doors, seals and door linkage are included with the housing. Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and vacuum actuators to the new housing.
Remove the rear seat airflow duct (18C420). For additional information, refer to Section 412-01 .
Remove the instrument panel (04320). For additional information, refer to Section 501-12 .
Drain the coolant from the radiator so that the coolant level is below the heater core (18476). For additional information, refer to Section 303-03 .
Recover the refrigerant. For additional information, refer to Section 412-00 .
Loosen the screw and disconnect the electrical connector from the powertrain control module (PCM) (12A650).
Disconnect the heater water hoses (18472) from the heater core.
Disconnect the vacuum supply hose.
Disconnect the condenser to evaporator tube and the evaporator to accumulator tube spring lock couplings from the A/C evaporator core (19860). For additional information, refer to Section 412-00 .
Disconnect the evaporator housing electrical connectors.
Remove the nuts and the washers at the cowl panel.
Remove the screws and the A/C evaporator housing.
Remove the screws and the metal cover.
Remove the screws and the A/C electronic blend door actuator.
Remove the A/C air intake flue damper assist spring (19917).
CAUTION: Do not attempt to bend any part of the A/C damper door shaft (19A580). It is brittle and will break. Depress the locking ramp and remove the A/C damper door shaft from the air temperature control door shaft.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. Remove the A/C evaporator case outlet door shaft (19B752).
Remove the A/C tube dash panel seal (19B588) and the A/C evaporator drain tube seal (19B739).