How difficult is to replace the A/C evaporator? I need to replace mine and they quote $450.00 if they do not need to remove the dash and $650.00 if removed is needed, ouch!

 

Never did it on the TL, but have done it on other cars that have needed the entire dash be removed to access the HVAC system. It certainly isn't a fun job, very time consuming, but if someone knows a particular car, it can be accomplished pretty quickly

Checking the FSM, doesn't appear that the dash needs to be removed:
Recover refrigerant
Disconnect the suction line and the receiver line from evap
Remove blower unit (looks like that requires glove box removal)
Remove throttle actuator control module
Remove climate control unit
Disconnect the connector from the power transistor, then remove the wire harness clip, the self tapping screws, and the expansion valve cover
Remove evap without bending the pipes

Why do you need anew evap?

 

My A/C stopped working: hot as hell here in PR!! The shop filled up with gas but sooner or later it will started blowing hot air again. Thanks for the detailed info.

 

it's a bitch of a job, but if you have some patience save yourself the cash, and do it yourself.

i had to replace my expansion valve a few weeks ago, so the evaporator had to come out. took me about an hour.

you have to pull the glove box, then the hvac fan, a dozen + screws, unbolt the expansion valve from under the hood, then slide out the evaporator.

 

There are more areas than just the evap where the refrigerant can leak, but maybe they used an electronic leak detector to pinpount the location.