mines done this for years....my A/C works just fine....the smell only barely comes and goes....I have found that if you turn on the heat just to defrost right away with the car not near fully warmed up, it fogs up the entire windshield and VERY SLOWLY defrosts it but it never seems to get all the fog from the entire windshield...my suggestion to you, which works for my 00' R/T is this:
1. make sure before u turn the car off, turn the defrost fan all the way off...
2. when u start the car and its cold outside, let the car warm at least 70% fully up...if not 100%
3. do NOT turn on the defrost before that amount of engine heat
4. slightly crack open the front window or windows, 1/4" or so...not even below the seal so snow can get inside, just enough to get a very slight breeze
5. once warm, turn on defrost to 3rd click, not full blast...seems to do worse at full blast
6. give it about 2 minutes, u r good to go....
I have found this method to work fine...sounds like a pain in the ass but its actually not....just cracking the windows a tad helps move air around and definitey helps defrost the windshield...I think the seals are bad on these windshields after so many years and if u don't replace it the fogging along the edges continually gets worse by the winter.....but evaporator cores, heater cores def a problem in these...dash removal isn't 7 hours...there are quite a bit of write-ups on the site to help u out...basic tools and patience and a helper will get u done alot quicker