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Hey all,
Car is a 2001 Trans Am. I replaced the compressor and a few other components in my A/C system. I was disassembling and handing parts to a helper, who was supposed to keep track of which o-rings and washers went where, but didn't. The full 3-volume maintenance manual doesn't seem to have the specific info of which o-ring is used where, nor can i find it on the internet other than "just match them up to what you took off" which obviously at this point i can't do. So we guessed when re-assembling.
System holds a vacuum but this joint keeps leaking after a few drives.
These are the three options from the kit that seem reasonable. I tried the rubberized washer (leaked, and after looking more closely at the groove in the condenser, i'm confident this was not correct). I've also tried the larger o-ring, which also leaked. Yes, i lubricated them with the recommended oil and i torqued the bolt to spec. I also used a manifold gauge set and really took my time adding R134a, used the table in the full service manual and stayed in the middle of the ranges for pressure on both the high and low side and the temperature from the middle vent on the dash was within spec. So i'm pretty confident i don't have an over-pressure situation. I have a slow leak at this joint (i can see the R134a bubbling out after a drive). No leaks anywhere else in the system.
The bottom o-ring is thinner and therefore seems less likely to seal so i haven't tried it yet. Can anyone tell me which one is the correct one to use, and/or what i may be doing wrong?
It sounds like you’ve done a lot of the heavy lifting already. Since you’re having trouble with a leaking joint, it might help to double-check the o-rings and washers for compatibility with your specific A/C components. Sometimes, even a small difference in size or type can cause leaks. If you have a local auto parts store or dealer, they might be able to provide you with a diagram or kit for your car model. Also, re-checking the torque specifications and ensuring that all components are properly seated might resolve the issue.
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A/C O-rings 
