Absolute yikes.
I'm dealing with this exact same issue -- blowing caustic aluminum salt particles all over my eyes and face (it burns!) when I try to use the vehicle, and it still manages to come through even if I turn the climate control off. The vehicle is basically unusable in this state.
Anyone have a better solution than selling the car and giving up? I actually rather like this car, and this is the only issue I've had with it so far (101,000 miles).
Ford wants $3,200 which is pretty much out of the question. Should I try using an aftermarket brand of evaporator core that doesn't have this alleged known factory defect?
I was also thinking about the fact that these are electrically driven compressors, I wonder if the voltage is leaking through the A/C components, causing this premature corrosion? If this is the causative factor, I believe this problem could be eliminated with a well placed ground strap.
I've also heard that I may be able to join a class action lawsuit over these premature evaporator failures, as they have been occurring very frequently on similar year Ford vehicles. Would love to hear everyone's thoughts and opinions.