HVAC Systems - Compressor Servicing Dodge Ram Van III

COMPRESSOR APPLICATIONS

COMPRESSOR APPLICATIONS (CARS)

COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS)

Removal

Remove compressor shaft bolt. Remove clutch plate and shims. Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub and shims. Remove snap ring, and remove rotor and pulley assembly. Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.

Installation

1. Install clutch coil so pin in back of coil aligns with hole in front compressor housing. Connect clutch coil lead. Install snap ring with bevel side facing outward. Ensure snap ring is properly seated in groove. Install rotor and pulley assembly. Install shims and snap ring. Install clutch hub.
2. Install dial indicator at front of clutch hub to measure clutch hub air gap. Using battery voltage, energize clutch coil. Proper air gap is 0.014-0.026" (0.35-0.65 mm). Add or remove shims to obtain correct air gap. Install compressor shaft bolt. On Concord and Intrepid, tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m). On all other models, tighten compressor shaft bolt to 10 ft. lbs. (14 N.m).

SHAFT SEAL

Note. Shaft seal replacement procedure is for 10PA17C compressor. Shaft seal replacement procedure for 10PA17 compressor is not available.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Remove clutch hub, shims, rotor and pulley assembly, and clutch coil. See CLUTCH ASSEMBLY. (Scheme 1)
2. Remove front housing. Remove felt holder and felt washer from front housing. Remove shaft seal snap ring. Position front housing (nose up) on cardboard, placed on a flat surface. Using brass drift, press shaft seal from front housing.

1. Lubricate NEW shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Using a 21-mm socket, press NEW seal into front housing, and install snap ring. Ensure shaft seal "O" ring side is facing the front housing (away from compressor). Install felt washer into felt holder. Using a 14-mm deep socket, install felt washer and felt holder.
2. Lubricate front housing "O" ring with refrigerant oil. Install shaft seal protector on compressor shaft. Install NEW front housing "O" ring on compressor assembly.
3. Install front housing on compressor assembly. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector.
4. Install through-bolts and NEW brass washers. Using INCH-lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 45 INCH lbs. (5 N.m) or less. Install clutch coil and check clutch hub air gap. See CLUTCH ASSEMBLY.
5. Using NEW refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and charge system. Perform leak test.

Scheme 1

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove pulley assembly. Using Spanner (MB991367) and Pins (MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor assembly. Remove snap ring and clutch coil. (Scheme 2)

1. Install clutch coil. Ensure projection on back of clutch coil is aligned with pin hole in compressor body. Install snap ring so that tapered surface is facing outward.
2. Install rotor assembly and snap ring. Align match mark of clutch plate with match mark of compressor shaft spline and install clutch plate. Using spanner and pins, install shaft nut.
3. Using a feeler gauge, check air gap between clutch plate and rotor assembly at more than one place. Air gap should be 0.016-0.024" (0.40-0.60 mm). If air gap is not within specification, add or remove shims as necessary. Install pulley assembly.
4. Using NEW refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and chargeA/C system. Perform leak test.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove pulley assembly. Using Spanner (MB991367) and Pins (MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor assembly. Remove snap ring and clutch coil. (Scheme 2)

1. Install clutch coil. Ensure projection on back of clutch coil is aligned with pin hole in compressor body. Install snap ring so that tapered surface is facing outward.
2. Install rotor assembly and snap ring. Align match mark of clutch plate with match mark of compressor shaft spline and install clutch plate. Using spanner and pins, install shaft nut.
3. Using a feeler gauge, check air gap between clutch plate and rotor assembly at more than one place. Air gap should be 0.016-0.026" (0.40-0.65 mm). If air gap is not within specification, add or remove shims as necessary. Install pulley assembly.
4. Using NEW refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and chargeA/C system. Perform leak test.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove pulley assembly. Using Spanner (MB991367) and Pins (MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor assembly. Remove snap ring and clutch coil. (Scheme 2)
3. Remove the bearing cover and retainer. Using Bearing Puller (MB991456), remove front shaft bearing. Remove snap ring.
4. Insert Lip Seal Installer/Remover (MB991458), into neck of compressor and catch lip seal tab. Remove lip seal from compressor by pulling it straight out.

1. Install Lip Seal Installer Guide (MB991459) over compressor shaft. Apply refrigerant oil to installer guide and to lip seal. Slide lip seal over guide and use lip seal installer/remover to install lip seal. Install snap ring. (Scheme 2)
2. Position compressor on a wooden support. Using a hammer and a 21-mm socket, install bearing into compressor. Install shims. Install clutch coil. Ensure projection on back of clutch coil is aligned with pin hole in compressor body. Install snap ring so that tapered surface is facing outward.
3. Install rotor assembly and snap ring. Align match mark of clutch plate with match mark of compressor shaft spline and install clutch plate. Using spanner and pins, install shaft nut.
4. Using a feeler gauge, check air gap between clutch plate and rotor assembly at more than one place. Air gap should be 0.016-0.026" (0.40-0.65 mm). If air gap is not within specification, add or remove shims as necessary. Install pulley assembly.
5. Using NEW refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and chargeA/C system. Perform leak test.

Scheme 2

CLUTCH ASSEMBLY

Note. On Cherokee, Dakota, Durango, Ram Pickup and Wrangler, compressor clutch can be serviced in vehicle, without dischargingA/C system.

Removal (Dakota, Durango & Ram Pickup)

1. Disconnect and isolate negative battery cable. Remove serpentine drive belt. Disconnect clutch coil harness connector. Without disconnecting refrigerant lines, remove compressor from mounting bracket. Support compressor in engine compartment.
2. Using spanner wrench, hold clutch plate and remove compressor shaft nut. (Scheme 3) Using a steering wheel puller, remove clutch plate, compressor shaft key and shims. Remove external front housing snap ring.
3. Install jaws of Rotor Puller (C-6141-1) into pulley snap ring groove. Install Shaft Protector (C-6141-2) over compressor shaft. Install puller flange plate on jaws. Install 2 Puller Through-Bolts (C-6461) through puller flange plate into jaws and hand tighten. Tighten pulley center bolt clockwise and remove pulley from compressor.
4. Remove clutch coil wire harness retainer from compressor housing. Remove clutch coil snap ring and clutch coil.

Installation (Dakota, Durango & Ram Pickup)

1. Install clutch coil and clutch coil snap ring. Install clutch coil wire harness to compressor housing. Align pulley and bearing assembly on front compressor housing hub.
2. Install Handle (6464) and Driver (6143) into pulley assembly bearing cavity. Ensure outer edge of driver rests firmly on inner race of bearing. Using hammer, install pulley and bearing assembly. While tapping on handle, guide pulley and bearing assembly to prevent binding. Ensure pulley assembly bottoms against compressor housing. Install external snap ring.
3. Install original shim(s) and compressor shaft key. Use a hammer and Shaft Protector (6141-2) to install clutch plate on compressor shaft. Ensure clutch plate has bottomed out on clutch shims. Replace compressor shaft nut and tighten compressor shaft nut to 10 ft. lbs. (14 N.m).
4. Measure air gap between clutch plate and pulley assembly in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If air gap is not within specification, adjust shim thickness as necessary. If air gap is not consistent around clutch plate, lightly pry up or tap down on clutch plate to make corrections. To complete installation, reverse removal procedure. Ensure A/C system operates properly.
5. After completing compressor clutch installation, start engine. Set A/C-heater control to recirculated air mode and high blower motor speed. Set engine speed to 1500-2000 RPM. Cycle compressor on for 5 seconds and off for 5 seconds, about 20 times to break-in clutch.

Exploded View Of Compressor Clutch Assembly (Typical). Scheme 3

1. Without discharging A/C system, remove compressor from mount. Install two 6-mm bolts in holes of clutch plate. Use 6-mm bolts and 2 box-end wrenches to hold clutch plate while removing nut from end of compressor shaft.
2. Remove clutch plate and shims. Using a plastic hammer, tap clutch plate to loosen from compressor (if necessary). DO NOT pry between clutch plate and pulley to remove clutch plate.
3. Remove pulley assembly snap ring. Remove pulley assembly. Disconnect clutch coil lead. Scribe marks on clutch coil and compressor for installation reference. Remove snap ring and clutch coil.

Note. Rotor/pulley assembly and clutch plate are a matched pair and should be replaced together.

1. Install clutch coil on compressor so locating pin engages locating indentation. Install snap ring with beveled side away from compressor. Secure clutch coil lead to compressor front cover and connect lead to thermal limiter switch.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. If reusing original clutch plate and pulley, old shims can be used.
3. If NEW components are used, install several shims so shim pack thickness is 0.10" (2.5 mm). Align machined match marks and install clutch plate and hold it tightly against shims.
4. Measure air gap between clutch plate and pulley surface. Air gap should be 0.013-0.025" (0.33-0.64 mm). Adjust shim thickness as necessary. On TRS-90, tighten compressor shaft nut to 13 ft. lbs. (18 N.m). On TR-105, tighten compressor shaft nut to 10 ft. lbs. (14 N.m).
5. Once compressor shaft nut is tightened, check air gap between clutch plate and pulley surface in at least 4 places. Readjust air gap if necessary. Install compressor. Evacuate and charge system. Perform leak test. Ensure A/C system is operating properly.
6. After completing compressor clutch installation, start engine. Set A/C-heater control to recirculated air mode and high blower motor speed. Set engine speed to 1500-2000 RPM. Cycle compressor on for 5 seconds and off for 5 seconds, about 20 times to break-in clutch.

Shaft seal is not serviceable. If excessive oil is present on pulley and plate friction surfaces or on compressor shaft nose area, replace compressor.