Hole in AC Cooling Unit Case - 2001 4Runner

[backcountry]

Hello all!

I'm the proud new owner of a 2001 Sport edition, and I've been very excited to discover such an active online owner's community.

Unfortunately, my first post here is about a problem I have just recently have come across. I am bit embarrassed to admit it, since I didn't find the damage before the purchase (but, really, the AC blew cold and I didn't think to inspect under the glove box), but I could use some advice. Here's the deal:

The other night I had a clipboard on the floor in front of the passenger seat, and when I got home I discovered that the clipboard was wet. I thought at first that a water bottle had just leaked, but I looked around a bit and discovered something worse.

Best I can tell, there is a hole in the bottom of the Lower Unit Case of the AC Cooling Unit (or at least that's how the FSM seems to identify it). I've attached a few photos to this post.

It doesn't look like anything else is damaged, just the lower case, and as I mentioned above, the AC blows cold.

I took it by a local independent Honda/Toyota shop, and replacing the whole assembly will be $1700. Not an option. They're willing to take it all apart, and try to replace only the case, but will still likely be several hundred dollar repair.

I'm willing to pull things apart myself, but have a few questions I'm hoping y'all can help with.

• It looks like I need to evac the system and pull the whole darn thing out in order to try to replace this lower case. Is that correct?
• If I do pull the whole thing apart, just how reasonable is it for me (handy, but not a mechanic) to take the lower case off and replace it?
• I've done some searching in the forums but couldn't find anything about this sort of thing. Do you have any threads you could point me to?

Perhaps more importantly: any suggestions on how I could make a reasonably good repair on this thing without actually taking it all apart?

For now I've taped a piece of plastic tightly to the bottom of the case. Is it going to damage anything if I leave this in place for a while? (Winter has started here in Washington state, so won't be using the AC much...)

Any suggestions for a slightly more robust, but still temporary, solution? I've thought of making a bit of a patch with J-B Stik or something, but I'm afraid it probably won't stick to the plastic of the case.

Thanks very much in advance for your thoughts and ideas!
Jim

 

[Singtoe]

Just replace the shell. Easy to do. It fits like a cartridge in the HVAC system. Only downside is you will have to vacate and recharge your AC system.

I have a AC shell if you want it. $15.00

 

[SJC4Runner]

Looks like someone kicked it too hard and it broke off? Do you see the piece that broke off anywhere? maybe under the seat? I would get some plastic epoxy and just glue it back together. If I couldn't find that I think I would find a plastic gallon container or a 2.5 gallon water jug and cut off a corner and use that in it's place and glue it in.

Alternatively find one in a junkyard, but if it's like my MR2's ac you would have to disconnect the AC lines to pull the unit out and replace the broken part. Then you would have to replace the drier for the ac and vacuum down the ac, add the correct oil and refrigerant. Not worth it when 10 bucks in parts and glue would see it done. Might not be pretty, just find a sticker for it

Note: Anytime you "open"(disconnect AC lines) the AC system you need to replace the drier/receiver. It helps remove any moisture that will get into the system.

 

[backcountry]

Thanks Singtoe, I may take you up on the that. The FSM indicates that the "packing" around the evaporator isn't reusable. Do you have any experience with that?

SJC4Runner, thanks for the reply. Unfortunately, I don't see the broken piece anywhere. I'm a bit concerned that nothing will stick very well to the plastic (I've only had minimal luck with plastic expoxy in the past), but am thinking I might make a patch with J-B Stick and then seal it with epoxy or silicone. Do you have any specific suggestions?

Could any AC experts comment on whether or not patching it will cause any problems? Last thing I want to do is fill the AC unit with mildew or something...

Thanks!
Jim

 

[badattitude]

Is any condensation dripping from the drian unter the truck? Make sure the drian is not clogged

 

[Singtoe]

Patching it won't cause any problems. You would have to make sure that it was totally water proof.

If I was going to replace the housing then i would gorilla hair (fiberglass) and some resin and glass it up. It will have to be done two times to get it nice and thick.

It should bond well with the existing plastic and provide a water tight compartment.

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[backcountry]

Thanks all for the feedback. I won't have a chance to deal with this until next month (for now the taped patch and a towel are my solution), but appreciate the help. Thanks again!