A/C conversion woes

[Mywifesidi]

Hello, this is my first post here after lurking through the universe of awesome info here. I'm attempting to convert my wife's 93 F350 7.3 IDI (CCLB 4x4, zf5) from a roasted non functional r12 to a "95" r134 setup. After reading lots of info, I felt this would be fairly straightforward, but it isn't. So I'm hopeful the powers that be here can straighten me out please My parts list was basically a rock auto list using a 95 f350 7.3 as reference. Maybe I got "rock auto'd" with a few incorrect items lol.
1) Evaporator size; most things point to "they're the same size. The old and new r12 (54541) units I bought are roughly 11" from pipe to pipe, the r134 (54558) from the 95 is 10", so this doesn't fit in the air box. Is there a specific evaporator I should look for? I didn't want to cut the air box. My solution now is install new r12 evap and have a conversion line from the new condenser made
2) Compressor mounting; I now notice the later trucks mount the compressor level and the vacuum pump at a 45 next to it. This truck mounts the opposite. This makes the new "95" accumulator to compressor hose way too short, pushes the compressor to condenser line into the power steering pump. Also, the plug on the new compressor is 90 degrees from the old one, conveniently farther away posing a small issue for the length of harness. Is the solution here to also have a special line made? Unfortunately my junkyard has nothing newer than a 92, I thought about seeing if the bracket was interchangeable.
3) Condenser: easily remedied, but the 134 unit is longer and doesn't fit into the latch support at the bottom. I cut the stud out and replaced with a long bolt and spacer.
That about does it for now, I'll add some pics and part numbers. I don't mind a scolding if I miss interpreted or just plain F'd up here, but anything would be a great help! Thanks again for everything this far!

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[Mywifesidi]

Attempting to load some pictures here...

 

[Kdo58]

On my 1987 I just put in new parts for my year of truck the only old parts were the lines which I cleaned out, put some 134 in it and it blows cold, and this was my first time doing ac.

 

[IDIBRONCO]

The 1995 is for a Powerstroke. Different engine, different parts.

 

[DougBoy66]

My 1994 has r134 and looking at your pictures all the components look the same or at least very similar to what is on mine. I know that isn't the best help but you may be able to use the same but new parts

 

[DougBoy66]

Well I went and looked at the parts I recently replaced on mine and they will not fit the 93. Now I am not an expert but, looking at 8some of the parts they are compatible with both refrigerant. So if you replace components and get the right internals it should work like @Kdo58 was saying. As long as you get the r12 out also like Kdo58 said

 

[Mywifesidi]

The original r12 setup was no good. When we bought the truck, the compressor had been removed over a decade ago and just left open. Condenser banged up bad from something going through the radiator, evap was loaded with crap. I figured it would get a overhaul of all new parts. So I lead myself wrong by reading 95 parts would bolt in and convert it to 134? I think my next course of action is having some custom hoses made to get everything connected. Thanks for the input guys

 

[DougBoy66]

Hopefully you find a fix

 

[Archieb89]

Did my whole ac system a couple months ago and had the same issue with the evaporator. Rock auto doesn't have the correct variation of it or they just dont make it anymore. The bracket for the accumulator is in the wrong spot and the wrong size. I drilled the rivets out both old and new brackets and swapped the old bracket into the correct spot on the new evap with a cheap pop riveter from harbor freight. The pic is before the bracket swap. I also had to bend the inlet and outlet tubes further apart by hand. Just be careful not to break them.

 

[Archieb89]

I also used butyl tape and red rtv to seal the hvac box and stuffed a little extra butyl in where it would not seal completely. Blows ice cold and doesn't lean any air now

 

[Archieb89]

The original r12 setup was no good. When we bought the truck, the compressor had been removed over a decade ago and just left open. Condenser banged up bad from something going through the radiator, evap was loaded with crap. I figured it would get a overhaul of all new parts. So I lead myself wrong by reading 95 parts would bolt in and convert it to 134? I think my next course of action is having some custom hoses made to get everything connected. Thanks for the input guys

You shouldn't need a different evap then what came with the truck. I bought the one specific to my year truck and like i said it still wasn't a perfect fit but the lines connect no problem. Evaps are all micro channel so it doesn't matter what year its from it'll work with any refrigerant. Same with the lines they'll take any refrigerant. Also you can get micro channel condenser for these older trucks off rock auto that'll bolt right up. I think you'd be better off just buying the right parts and not paying to have hoses custom made that'll be difficult to get if you ever need a replacement.

 

[mf7lakes]

These guys down in Florida build A/C hoses -- probably if you talk to them & send them original stuff, they can match & rebuild new lines to match

Cold Hose

AC Hoses, Hose Kits and Fittings, AC hose repair

coldhose.com

 

[Reggie f250]

I have a 92 and I converted it to ac from non ac by taking the entire system from my 94 f150 5.0. Everything fit and works. The only problem I had was the compressor hoses angled wrong. The low pressure hose needed to be angled up to fit and the high pressure hose was too long so I curved it around so it would connect to the condenser. I found out later my core support is bent from the previous owner using it to pull something with it so my condenser dropped right in. Repositioning the support would be a good fix for that. I think the only other parts that would fit better would be for the 94 because thats the first year for 134a and the last year for the idi.

 

[hce]

The r12 evap and condenser are adequately sized to be used for r134, there are no need for changes. If the compressor failed as a result of black death, then it is advisabe to replace all componets. Almost all replacement ac products that can be purchased are for r134 use even if the vehicle was R12. Original hoses can be questionable, r12 hoses are too porous for r134. There is the claim that r12 hoses that have been oil impregnated will seal for r134. O rings should be updated. Possibly flushing for oil especially if changing the compressor. Dryer needs to be compatible for the oil, most likely anything you can buy is for r134.

 

[CDX825]

Ive converted a couple of these trucks and always just used the factory R12 evaporator and condenser. Change all the O rings, Change the accumulator, Change the orifice tube to red or orange, Use ester oil NOT PAG oil. Vacuum and charge by weight. Sometimes have to adjust the pressure switch on the accumulator so they cut out lower to. The factory R12 stuff works great when converted right.