Chrysler Repair: 2002 Chrysler T&C: Evaporator leak?, hayes manuals, leak rate

Question
Hi Roland,

Our 2002 T&C stopped blowing cold air a couple years ago.  We had it tested on more than one occasion, but no one has been able to find a leak and the system holds a vacuum when on a machine.  I have put freon in with dye but cannot see any signs of a leak.  A full charge leaks low enough to kick the low pressure sensor and shut down the compressor in about 5 days of use.  One shop suggested it could be the evaporator...with a price tag of about $1,500 to replace.  From what I'm reading it is a job that involves pulling the dash to get to.  Is there any way to be SURE this is the problem before committing to such a cost?  Finally, what repair manual would you recommend if I were to tackle the job? I've used Hayes manuals in the past on other projects but can't seem to find them anymore.

Answer
Hi Brandon,
It would be better to keep searching for the leak than to take a guess that replacing the evaporator will solve the leak. Keep speaking with AC shops about techniques that might help find it. I wonder about a gasket leak at interconnections between parts as a possible low leak-rate source.
The procedure is lengthy but is covered in several parts of the '02 service manual which I have and can xerox copy the pages for you. It costs me 10 cents per side.
Tell me a postal mailing address if you want to go that route.
Roland