Oh My Gosh, I know one thing for sure.... you should test the new evaportor for leaks BEFORE you install it... All that work and THEN find out it leaked... Just could not stand that heat...

It sounds like you have more experience in this department than anyone else I know of ... there was one student i think in Florida who took his apart and put it back together TWICE... but I have not read of anyone having attacked two different dashes... and live to tell about it...

ANYTIME the system is opened up the Reciever Dryer is supposed to be considered KAPUT... it takes almost no time out in the open for it to get saturated with moisture... and the oil in it does not give up its moisture when one evacuates a system in the normal way...

The expansion valve would not have to be replaced... but it is cheap ... and if you wanted to that would be the logical time...

Good luck... and take lots of digital pictures both for you sake putting it back together and for us to see...