Bill,
Let me share my A/C story. We are frantically trying to get ready for Sharkfest. Our 95 3500 dually has about 95K on the clicker. We have owned it for about two years and have hardly put more than 3K miles on it. She is loaded down with all the goodies including a/c.
I noticed after driving for a while it would stop blowing air through the vents. Turn of the air for a few minutes, click it back on, and all was well. Considering I hardly use it, I would forget about it by the time I got home.
I finally popped the hood a couple of weeks ago after about a 1.5 hour cruise (air had stopped) and found the entire low pressure side of the a/c system covered in a layer of thick white ice. Therefore, my evap was freezing over not allowing any air to travel.
Most of the time this is a symptom of low freon (freezing up). I opened the system only to find somebody else had been there and it was full of glow in the dark green die. I went through the system finding nothing wrong other than the fact the a/c clutch was ALWAYS engaged when turning on the air. No obvious defects.
So, a new drier, orphis, oil, o-rings, and hours of my time later, she had a fresh full charge of freon. Low and behold, she was never cycling. I also installed a new cycle switch, and high pressure cut out.
At total frustration I accidently (just like you) found that some prior owner had gone down about 3" in the harness for the cycle switch and spliced the wires together. Thus giving the signal that all was well all the time to the system so it kept the clutch engaged regardless of the cycle switch position. ARGHHHHHH. I could have had it cycling for ten minutes, some solder and heat shrink!
To add insult to injury. All was well, system cycling, and life was good. On the way home from church yesterday she starts blowing HOT AIR! After doing all the normal checks, I find out that the outer clutch pull ring was too far away from the pulley. I closed the gap, and it seems to be cycling and working now.
BUTTTT, on the way into work with it this morning, the brake lights quit working (fuses and relay good-acts like a bad ground).
Man! Some things just won't work with me!
Glad you found it. Like with me finding the spliced wires, it is a relief to be a simple problem, but you kick yourself in the butt for not finding it sooner.