A/C evaporator broken, quoted $1,800 to fix

I'd get a second opinion.

Maybe there's another TSB that mentions the evaporator, but the one linked below does not.
They simply add an auxiliary fan to combat poor AC performance at idle.

https://static.nhtsa.gov/odi/tsbs/2019/MC-10166026-9999.pdf

 

I’m curious too, 2019 here.

 

I don't think it ever was. The TSB never mentions it and there have been other complaints of condensation dripping from it. Never have I seen a mention of a redesign for it.

Sucks for OP but I think this is just shit luck. Doesn't seem to be a common failure.

 

Did you post in the wrong thread by chance? I'm a bit boggled with what a 2004 Ford has to do with anything here.

 

I’m not sure. The service adviser said the part was a new revision. It’s even written on the estimate that way.

perhaps that was a lie to get me to have them do the work rather than ordering an aftermarket evap core and hiring a private mechanic? “Ours is a NEW and IMPROVED part!” ?? Who knows.

I have a call into Toyota about this, but I missed their callback today because I went out to get the mail. They called during a 45 second window when I didn’t have my phone, I swear to God.

 

Sorry OP this sucks. Regardless of who pays, if you can find a dedicated Auto AC shop that may be best. They are hard to find though. They are used to taking interiors apart. Next best, but more complicated, is going to an upholstery shop and have them remove the dash, then bring to a repair shop for the EVAP core (or use a mobile mechanic), and reassemble. I did this with a Mustang years ago for a heater core. I wanted it taken apart and put together with care by folks who know interiors, not mechanics.

 

The evaporator in my 2nd Gen (2010) sprung leak in 2017 at like 75k miles. Thankfully, the A/C never outright failed. It blew ice cold out of the driver's side, but warm out of the passenger side; My old mechanic charged it twice but could not find the leak. Having lost patience, I brought it to the local dealer in August 2018 when it got progressively worse over the course of a weekend (but still didn't fail entirely); They found it to be about a pound low on refrigerant and charged it up, along with UV dye. I brought it back in September and thanks to the UV dye they traced it to the evap core. I wanted my A/C fixed and the dealer had a free loaner vehicle, so I paid almost $1,600 to get the evap core replaced; The system had to be evacuated and disassembled when they replaced my frame in November 2021, but I have no had any problems with the A/C in my truck since August 2018.

My truck uses R134a, but I'm assuming that yours uses R1234yf?

 

OP, after rereading your post, when you say it is 'blowing warm" is that all the time or just some of the time? If it is just some of the time, you likely don't 'need' a new evaporator. There have been complaints of poor cooling on some trucks (I think out west in hot temps) at low speeds and that is where the aux fan (TSB) was installed. Although I really don't understand the issue because I have a 18 and it cools fine under all conditions. It would seem to be a charge issue or fan clutch issue.

 

Evaps have become so thin and cheaply made these days I wouldn't be shocked at having one leak. Toyota definitely didn't make them serviceable. $1800 is about right for dealer pricing. You could probably get it for half that at a local A/C shop. I would however confirm that it is the evap leaking. That is done with dye and a camera. If it leaking your only option is to replace. The TSB has nothing to do with thin metal or poor welds.

 

I don’t know what method they used to determine it was the evap core. I don’t think they did anything with dye but I dont know for sure.

I’m going to try to reach Toyota corporate tomorrow and if they decide not to help me, I’ll probably just pay for a recharge.

I have a relative who had the engine in her Ford suv seize, because the head gasket failed and it mixed lots of coolant into the oil during a 3.5 hour trip. It was VERY out of warranty, but the dealership called Ford on her behalf and got her a free replacement engine because those head gaskets were a known issue. She didn’t call anyone. Fords may be unreliable garbage but that level of loyalty to customers blew me away.

 

SITREP: Toyota is covering it 100%. That is awesome of them. I am a lifetime customer now.

 

Had to have the evaporator in my 2010 replaced back in 2018; Cost just under $1,600 at the dealer...

 

My sisters’ Audi Q5 and my brother in laws’ Honda Civic both have A/C down right now, and both are because of an evap core failure! Go figure. Makes me wonder if there’s only 2-3 companies that make these things and lots of car companies source the same ones . . . .

 

Luckily, my A/C never outright failed; It always blew ice cold out of the two driver's side vents, sorta cool out of the middle right vent, and warm out of the far right vent. It took over a year and a half and three recharges before the leak was found...

 

Sure is good advise. Maybe I'll use it someday. Good Luck OP and i agree yours must have had something buggy if it turns out to need that job.

 

Next bit of advice. It's a bear to do the evap core, so do the tech a favor and clean out the front of the truck, remove all accessories.

Next right as you drop it off, take pictures of the dash and steering wheel. Just incase they scratch anything.

 

My truck was over 7 years old and had like 75K miles when the problem manifested itself in June 2017; I wouldn't have noticed it if I hadn't reached across the cab on a humid day to unlock the door or something, and realized that air coming out of the far right vent wasn't cold.

 

Good advice, thank you. Yeah I had planned to empty out the glove box and center console, and take pictures and video of everything working properly just in case something is broken during disassembly.

 

Got the truck back. Everything looks and functions great. No issues with damage to the dash or loose / rattly interior trim. Drove it about 75 miles today. It all feels and works as good as the day I dropped it off. I am very thankful to Toyota USA and to Maguire Toyota in Ithaca.

If anyone else has a similar issue with their A/C, turns out the exact TSB is 0004-22, which calls to remove / replace the HVAC Evaporator sub assembly (which is BURIED in the dash).

https://static.nhtsa.gov/odi/tsbs/2022/MC-10207964-9999.pdf

 

probably going to have to get this on my truck. i actually have a leak coming from a seam from under the evaporator housing box as well as the whistling noise.