I tore it down. The the orifice tube for front AC got plugged. Then the rear expansion valve got plugged. After which the compressor built up so much pressure it blew out the orifice tube.
I cannot seem to find metal debris although some of the debris in the expansion valve is quite suspect as such. However, cannot be picked up by a magnet so I'm not sure what it is.
I ordered a new dryer, expansion valve, orifice tube, and o-rings. I think my compressor is good but hate to waste $100 in parts and refrigerant to find out. It seems the AC had been worked on in as early as 2013 (date stamped on accumlator / dryer).
Here's what I plan to do.
(1) blow out parts as best as possible with compressed air and brake parts cleaner.
(2) Put back together with a new orifice tube and cleaned up expansion valve.
(3) Replace locations where I found faulty o-rings
(4) Charge system with cheapo dust off and run for a while (works great and is cheap).
(5) Test for leaks with dust off in the system - run it for a few days.
(6) Evacuate system. Check the orifice tube and expansion valve for debris.
If clean,
(7) Rebuild with new dryer, orifice tube, and expansion valve.
(8) charge with correct refrigerant and oil as necessary.
I made a video of my diagnosis below.
Curious as to what you guys think the debris maybe or where it came from? Also if you think I could go about this another way? I'm not terribly experienced with AC.
Youtube Video of Truck Teardown
Youtube Video of Debris:
I'm moving this thread to here:
https://www.tahoeyukonforum.com/threads/identify-source-of-material-clogging-up-ac.111271/