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Originally Posted by G-Benz
The original evaps were aluminum...these were prone to failure. The replacements are copper (which is what it SHOULD have been from the start).
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This is not a true statement regarding the material selection. I have had many, many flawlessly operating (long term) evaporators made out of aluminum. Aluminum when properly passivated is more corrosion resistant than copper, while maintaining high heat transfer capability.
The problem is thus elsewhere, either in the design of the evaporator core, or in its manufacture.
Also, an evaporator core should only cost around $350 or so max, not $900.
As for the work. Yes, removing a vehicle dashboard is a ton of work, moreso on the Benz. I would take the opportunity to replace the heater core as well and check all of the other climate control components.
If it were me, and someday it will be, I'd take this project on myself, except for recovering the refrigerant. I can flush, vacuum and recharge, but I don't have an approved recovery apparatus.
The other thing to consider is this: Every time, for whatever reason, if I have to crack open an A/C system I always 1) replace the dryer, 2) remove inspect and flush the expansion valve, condensor and line set and 3) replace ALL o-rings and seals. I also consider removing the compressor to drain the old oil, flush, inspect and refill with new oil. Doing all of this has led me to many trouble free miles on every A/C system in my family's vehicles with no other issues out of the eight systems I've worked on so far. I did have trouble with a blown compressor on one car that I converted from R-12 to R-134A after two and a half years, and so I replaced the condensor, compressor, dryer, expansion valve and converted it back to R-12 and it hasn't had any problems in the last five years.
32 years experience turning wrenches, mechanical engineer, and more importantly a certified A/C tech...
Good luck either way you go with it.