Fan didn't engage this morning, so I pushed all the buttons and turned the temp dial and still no moving air. Nothing on defrost, heat or a/c, but I could hear the clunk and the lag of the engine while the compressor engaged. I drove about 2 miles trying to figure it out.

Popped the hood and the low side hose and port was frosty. I shut off the a/c and then the engine. Frost started to disappear right away. Waited a minute with the engine off, checked the fuses (not the relays), and restarted. Fan came on and cold blowing air just like it's supposed to.

CC Unit is a reman - not a junkyard
Compressor is new
Condensor is new
Rec/Drier is new
Expansion valve is new

This sounds to me like a motor/brush issue. Any other guesses? Do relays go bad slowly or just crap out?

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

did you check the strip fuse on the shock tower, its a 30A fuse and its for the blower motor, its pretty annoying as it develops microcracks in it meaning it looks perfect - I always touch it in the midde if I want to test it.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Worn brushes could cause blower problems. The usual symptom is failure to operate at low speed. Pushing the high speed button will get the blower going, then you can press the variable speed or low speed button and the blower will operate normally until next time.

A blower controller failure usually results in complete blower failure or sometimes gives a blower that operates at only one speed.