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Cool, let us know how it works out. Also doing a bit of study on this type of AXV it also employs some properties of a TXV which is probably why it is used in so many places. Pressure buildup On the outlet of the evap applied to the diaphragm, relaxes pressure on the rod allowing the ball to...

The stumbling block, pardon the pun, may be the block itself as that most likley has the machined passage/orifice that controls the overall flow rate. So the guts may swap, but If you are using the original valve block, you are stuck with the same machined passages. I would compare the passage...

I think a 1 1/2 and a 2 1/2 Ton valve would use the same diaphragm, rod and spring as they both need to cutoff at Around the same pressure... I think where they are different is that the 2 1/2 ton has a significantly larger (60%) internal orifice And perhaps A little different size valve to...

They use AXV’s in a LOT of places, so their shortcomings cannot be that great... there are two types, one with the spring on the diaphragm side, that was what was confusing me as that spring pressure on that type is increased to open the valve. This type balances the force between...

ok, I missed your edit above. How did you get to the 3 1/2 turns, all at once or in slow little steps Monitoring pressure and temp? does your accumulator have a site-glass on it? One thing that could be happening is that you are indeed low on refrigerant and turning up the AXV or putting in...

A TXV might have a slight edge in a wildly varying environment, but the AXV is simpler/more robust, not orientation sensitive and should get you acceptable performance. Again, if you are rolling temps below 32F you risk evap freezups. 35-40f outlet air should do a good job for you if all the...

Ok, well an AXV simply maintains outlet pressure on the evap. So either it is set too low(sure there isnt an adjustment screw on it, that is usually how the low pressure is set to match the flow). Or something else in the system is restricting the flow or the compressor isnt working to spec...

Well if you can get all the air to pass thru the evap, you shouldn't have to relocate the bulb... one of the main functions of the TRV and its temp sensor/bulb is to keep the evap from freezing the condensed water On the evap...

Well air going around the evap isn't being chilled:)

Well you could pull the TRV, warm its bulb and back-flush it with compressed air...

Low coolant or low coolant flow. Since your testing shows it isnt low coolant and with the high pressure split, Perhaps the TRV(Or somewhere else in the circuit) has an obstruction Which isnt letting the refrigerant flow properly... Are the condenser fans operating and giving good flow thru...