I had to unsnap the lower fan / evaporator housing and pry it open and wedge a hammer handle since I couldn't find what connects the portion near the floor / firewall. I got creative with our flexible dryer lint brush and scrubbed that boy finally just grabbed the hose and its clean again. all is good again. I will be doing the cabin filter mod soon. also think im going to add a drain tube elbow or hose as the stock drain is a straight shot for dirt / dust to enter.

 

So I pry open the ac box to peek at the evaporator and its completely covered with junk, I used a lint dryer tapered brush and a garden hose and its finally clean. Why in the world is there no cabin filter is beyond me. New blower motor installed and same results. I honestly forgot about it last year as it cooled off and didn't use the ac. Last month I remembered.. 93 and no air still but only on long trips. I did have quite a few blocked bent fins on the condenser from bugs and hail. Got a radiator fin comb and painstakingly fixed it all. Yep that's not it either. I replaced the Evaporator temp sensor, nope that didn't do it. Just got a new expansion valve in the mail today, since I was told there is no orifice filter inline and so we will see. My son has a AC evac machine but wont be home till Friday.

 

Sorry for long delay but it turns out that it was the expansion valve. A 12.00 amazon part. I still think there's an airflow issue since it couldn't blow out a birthday candle on recirc high setting. Also replaced blower motor and same result. But it's cold finally full time. .. maybe I'm expecting too much but my wife's Malibu will know off your ball cap on high setting.