2006 CE - A/C Condenser Needs Replacement

[wrx341]

I own a 2006 Toyota Corolla CE (Manual transmission) with about 24,000 miles on it. This car has been absolutely perfect...until a couple of days ago, when I discovered that the air conditioning no longer worked. You know how your car idles a bit higher and loses some power when the A/C is running? This wasn't happening. The compressor failed to start up.

So, the next day, I took over to one of three Toyota dealerships in my city. The service technician assured me that it was probably an electrical relay or, at worst, the air conditioning clutch. I received a call a few hours later. As it turns out, a rock punctured the condenser, causing all the refrigerant to leak out. Since this isn't considered a manufacturing defect, it's not covered by the warranty. $500 for a new condenser.

I opted not to have it replaced. I quickly called Toyota Motor Corp. and complained. The customer service rep dispatched a file number to the dealership and told me that they (Toyota Motor Corp.) would see what they could do. Sure enough, the dealership concluded that since it isn't a manufacturing defect, it won't be covered by the factory warranty. Upon calling Toyota Motor Corp. for the second time, they concurred. I was given the analogy, "This would be like running over a nail, getting a flat tire, and expecting the tire manufacturer to pay for it." Yes. It's *exactly* like that.

This has to be a design flaw. Plain and simple. 99.9% of my driving is done on paved roads. A Google search revealed that the only car that seems to have this problem are the previous generation Honda Accords. Which brings me to my questions:

1. Even if the system were to have no refrigerant in it, shouldn't the compressor still be kicking on? Any possibility that it could still be an electrical problem? Any possibility that the dealership is trying to screw me over? (Hah. I should know the answer to that one already.)

2. What should I do at this point? I'll be writing a letter to Toyota Motor Corp., as I've heard of stories where automakers will pay for unusual repairs if you complain enough.

3. Even if the condenser were to get replaced, what's to stop this from happening again? Do I really have to worry about small rocks damaging the A/C system in my car from now on?

I apologize for the long post. Thanks to anybody that has taken the time to read this.

[Raddman]

I don't believe it will kick in if it's empty of freon...Do you know for sure you have a hole in your condencer, meaning did they show you?...Cars A/C will go into a safe mode if there is no freon, just like a radiator fan will kick on if a relay goes bad....If you know for sure you have a hole then why do you think it's electrical, you still have to replace the condenser?...Do it yourself lt doesn't look that hard of a repair...Also looking around I found some on eBay new for under a $100 ands other websites for around $200....BTW their right about the nail in tire theory just like getting a broken window from a stone, if you have a low deductible maybe your insurance can help, if you don't really know if it has a hole in it take is for a second opinion, some will do it free! Good luck and keep us informed on what happened...

~Radd

[ghost_ryder35]

it isnt a manufacturing defect as the told you, however you might be able to tell them the defect lies within them not protecting the bottom of the car enough when they designed it with splash shields and whatnot. I'd just let them fix it though so later on it will be covered. I highly doubt you'll be able to win this battle.

[retiredat44]

the cost of the condensor is the cheap part, even if you go for a good deal on eBay, you will take it to a shop to have it refilled. and since the a/c system is going to be opened up, to fresh air, they will need to do a full a/c service and refill. They have to vacuum it dry of all air, and then make sure the proper amount of oil is already in it, or refill the oil too. Only way to do that is to empty the compressor and refill that. So, best thingg if you n eed to save money is to replace the condensor yourself. get new O-rings for each of the parts you take apart that uses O-rings.

You might be able to get the whole job done for less than $300.00. Which isn't bad. it could be much much worse.

IMHO

[Tango]

I have to agree with them on this one. Check with a local shop, or an airconditioning and radiator shop. They will be a lot less than the dealer.

[the4starish]

I have the EXACT same problem. Im looking at doing it my self only, I have no idea on how to install or remove it, but to save a few hundred bucks, I'm all for reading a DIY. I'll keep you posted on what progress I make and I hope you can do the same.

[Raddman]

Originally Posted by the4starish

I have the EXACT same problem. Im looking at doing it my self only, I have no idea on how to install or remove it, but to save a few hundred bucks, I'm all for reading a DIY. I'll keep you posted on what progress I make and I hope you can do the same.

I hope you have all the equipment to blow out the system because any little particle left inside will will block something....Check what retiredat44 posted...

~Radd

[retiredat44]

I say replace the condensor yourself, off ebay, like I said Less than $100, most probably. Get new o-rings, from ashop like Napa Auto. But then take it to a auto a/c shop to vacuum and refill it. You will come out much better my way. Don't attempt to refill it yourslelf. You may or maynot get lucky. Don't chance it. Do not worry about oil, have ths hop make sure it has the correct amount. Don't just pump new freon (R134a into it) yourself. It's harder than you think. It takes special gauges and knowledge. As you will have the a/c system completly opened up, and it must be vacummed out. I am trying t save you from pure hell and lots of wasted money.

you can tell the shop it worked perfect, never had aproblem, and a smal rock puncntured the condensor. You bought one off eBay (or where) replaced it yourself and replaced the o-rings. A good shop can take it form there.. When you work on it, work in a sterile clean environment with no wind or dirt. Low moisture if at possible.


good luck

[the4starish]

Exactly, I plan on buying a condensor off of eBay and having it installed, filled and recharged at a local Radiator and Cooling System Shop. I added it all up and I'm looking at around $350 for everything when all is said and done. He also said that he could repair the my old condensor for $70 if I can remove my old one my self. So I'm not sure what I should do. How much does it normally cost to have a condensor recharged, refilled, and vaccuumed out?

[Flashmn]

I have the EXACT same problem. Im looking at doing it my self only, I have no idea on how to install or remove it, but to save a few hundred bucks, I'm all for reading a DIY.

That DIY can end up costing more than the few hundred bucks you're gonna save.
The connectors are very sensitive, too tight, you'll mess them, too light and you're gonna leak everything out. Somethings are best left for the pros.

[sponger]

damn that sucks, man. reminds me of when a friend of mine ran over an unknown object in her '03 beetle and not only did it flatten her tire, but it also cut some electrical line of some type or another. This caused the battery to die early, and according to the dealership, since it was some kind of special battery, the bill was like $600-$700 total to fix everything. Since when does a flat tire mean a cut electrical line and a dead battery?