i live in south carolina and its about to start getting so hot here and i need some serious help. I have a 1996 Bonneville se and i get low air flow from the vents. All the setting works (from vent, floor, windshield). I removed the evap core and clean it, new blower and resistor. What could be the problem? oh yea, the air gets freezing cold just not enough air through my vents

In your troubleshooting so far, you have confirmed that the evaporator core is clean, and that you have a good air flow when the defroster or floor vents are selected. You also had an auto parts store check for a vacuum leak on the actuator door that switches between vents and defroster. They found no leak. You also mentioned that there was a few small dents in the fins of the evaporator, but it was believed that was not causing the issue, as the air flow is great coming through the vents or the floor, all of which comes through the A/C evaporator.

At this point, I would check for air leaks in the duct work, the only other thing would be to physically confirm the vent flapper door is working properly.

I don't know how different of an answer you will get here, but remember we can only help you as much as you can help yourself, and there was still some questions that were answered. What is the flapper door doing, and is there an air leak some where?

I have a totally new evap core, the flapper is under the driver side correct?

Anyone?

somebody should be able to help soon thanks!

How can i check to see if the duct door opening all the way