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On the Gen 2 anyway the holes have to be drilled in the cab for the AC fittings. The heater coolant fittings are the same as the non-AC box.

It seems (based on forum posts and youtube videos) that a not insignificant number of installations are using some aftermarket repurposed automotive style condenser core - usually these are like 1/2" to 1" thick and have VERY tiny flat tube construction so they hold only a small amount of...

Sounds like it. Whoever wired it might have wired the fan current through the switch and it's probably not rated to handle it. This burnt out the contacts in the switch. A possibility you should investigate anyway.

If you have the full gen 2 system with the military condenser, etc - the official capacity is 4 pounds (64 Ounces). I was advised by an experienced Motorpool vet that 3.5 lbs is usually where they find they work well.