A/c Compressor Overhaul Ford Econoline E350

Removal

1. Remove compressor shaft nut using Spanner (T70P-4067-A) for FS-6 compressor or (T81P-19623-MH) for 6P148 compressor. Thread Hub Remover (T80L-19703-B) into clutch plate. Tighten center bolt in hub remover to remove clutch plate and shims.
2. Remove snap ring. Remove pulley assembly from compressor. If assembly cannot be easily removed, place Shaft Protector (T80L-19703-G) over shaft. Using Puller (D81P-19703-B), remove pulley assembly. Remove clutch coil retaining snap ring. Remove clutch coil.
3. If bearing replacement is required, place pulley on Support (T80L-19703-E). Using Bearing Remover (T80L-19703-J), drive bearing from pulley.

Scheme 1

1. Place pulley on support if replacing bearing. Drive replacement bearing into pulley using Bearing Installer (T80L-19703-C). Stake pulley in 4 places to retain bearing.
2. Install clutch coil on compressor so locating pin on compressor engages hole in clutch coil. Install snap ring. Using hammer and Pulley Installer (T80L-19703-J), tap pulley assembly onto compressor.
3. Install snap ring with beveled side away from compressor. Using Clutch Plate Installer (T80L-19703-F), install clutch plate and shims. Install and tighten compressor shaft nut to 10-14 ft. lbs. (14-20 N.m). CAUTION: DO NOT drive clutch plate onto compressor. Use clutch plate installer to prevent damaging compressor. DO NOT tighten compressor shaft nut with air tools.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 locations around pulley. Rotate pulley 180 degrees, and recheck clearance. Proper clearance is .021-.036" (.05-.91 mm). Adjust shim thickness to obtain correct clearance.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure drained amount.
2. Remove clutch assembly. Ensure compressor outer surface is clean. Mount compressor on Clamp and Holding Fixture (T81P-19623-D) for Ford FS-6 or (T81P-19623-PH) for Nippondenso 6P148. Place fixture in vise.
3. Using Key Remover (T81P-19623-NH), remove key from compressor shaft. Remove front head retaining bolts. Remove front head. (Scheme 1)
4. Remove dowel pins from front head. Lift inlet reed valve assembly from front head. Using Valve Plate Remover (T81P-19623-B) for Ford FS-6 or (T81P-19623-PH) for Nippondenso 6P148, remove front valve plate assembly from front head. Remove shaft seal assembly and felt seal from front head.
5. Using hammer and Shaft Seal Seat Remover (T81P-19623-OH), drive shaft seal seat from front head. Clean components with solvent. CAUTION: DO NOT dry front valve plate assembly or inlet reed valve with compressed air.

Installation

1. Place dowel pins in compressor. Lubricate inlet reed valve with refrigerant oil. Install inlet reed valve on compressor. Install front valve plate assembly on compressor. CAUTION: DO NOT touch sealing surfaces of shaft seal or shaft seat assembly.
2. Lubricate shaft seal seat with refrigerant oil. Position Seat Installer (T81P-19623-C) on new seat so installer is placed on raised side of seat. Install shaft seal seat.
3. Install shaft seal assembly in front head so sealing surface is toward end of compressor shaft. Ensure flat areas on shaft seal assembly engage with flat areas on compressor shaft.
4. Lubricate front head "O" ring with refrigerant oil. Install front head and "O" ring. Tighten retaining bolts in a crisscross pattern to 19 ft. lbs. (26 N.m). DO NOT use air tools to tighten retaining bolts.
5. Install clutch assembly. Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Perform leak test.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T70P-4067-A), remove clutch plate retaining bolt and discard. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shims.
2. Remove snap ring, and remove pulley assembly. (Scheme 2) Disconnect electrical wiring from clutch coil. Install Shaft Protector (T89P-19623-FH) on nose opening of compressor.
3. Install 2-jaw puller on compressor. Tighten puller to remove clutch coil from compressor. DO NOT use air tools when removing clutch coil.

Scheme 2

1. Ensure clutch coil mounting surface is clean. Install clutch coil. Ensure electrical connection is correctly positioned. Install Coil Installer (T89P-19623-EH) over compressor nose and inner diameter of clutch coil.
2. Install 2-jaw puller on compressor and coil installer. Engage jaws on puller with compressor front mounts.
3. Tighten pressure screw, and install clutch coil. DO NOT use air tools when installing clutch coil.
4. Install pulley and snap ring. Install snap ring with beveled side away from compressor. Install shims and clutch plate. Install NEW clutch plate retaining bolt and tighten it to 96-120 INCH lbs. (11-14 N.m).
5. Using a feeler gauge, check clearance between clutch plate and pulley assembly mating surfaces in 3 places. Clearance should be .018-.033" (.46-.84 mm). If clearance is not as specified, add or remove shims to obtain proper clearance. NOTE: When new clutch assembly is installed, cycle clutch assembly 10 times with engine at idle to burnish clutch and prevent slippage.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T70P-4067-A), remove clutch plate retaining bolt and discard. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shims.
2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Using Snap Ring Remover (T89-19623-OH), rotate eye of snap ring. Pull up snap ring while holding snap ring at a tilt angle.
3. Position Shaft Seal Remover (T89P-19623-BH) over compressor shaft. Push shaft seal remover downward against seal. Ensure end of shaft seal remover engages inside of seal.
4. Rotate shaft seal remover handle clockwise to expand remover tip inside seal. Pull shaft seal from compressor.

1. Shaft Seal Protector (T89P-19623-CH) is included with replacement seal kit. Lubricate shaft seal protector and shaft seal with refrigerant oil.
2. Install shaft seal on Shaft Seal Protector (T89P-19623-CH) so lip of seal is toward compressor (large end of shaft seal protector). Install shaft seal protector on compressor shaft.
3. Using Shaft Seal Installer (T89P-19623-AH), push down shaft seal until it is seated. Remove shaft seal installer and protector. Install NEW shaft seal retaining snap ring.
4. Install NEW shaft seal felt. Install clutch plate. Install new clutch plate retaining bolt and tighten it to 96-120 INCH lbs. (11-14 N.m).
5. Using feeler gauge, check clearance between clutch plate and pulley assembly mating surfaces in 3 places. Clearance should be .018-.033" (.46-.84 mm). If clearance is not as specified, add or remove shims to obtain proper clearance.

1. Disconnect negative battery cable. Loosen and remove belt. Disconnect electrical connector. With refrigerant lines attached, remove compressor mounting bolts, and position compressor for service.
2. Using Clutch Hub Holder (6355), remove crankshaft nut. Using Clutch Hub Puller (6354), remove clutch hub and hub clearance shims.
3. Remove retaining snap ring and pulley assembly. Remove snap ring and clutch coil assembly.

1. Align hole in back of clutch coil with pin in compressor housing. Ensure clutch coil electrical wiring is properly routed. To complete installation, reverse removal procedure.
2. Tighten crankshaft nut. Using a feeler gauge, check clutch plate-to-pulley clearance. Clearance should be .020-.035" (.51-.89 mm). If clearance is incorrect, add or remove shims behind clutch hub as necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove compressor. Drain oil from compressor, and measure the amount of oil drained. Remove compressor clutch assembly.
2. Remove compressor crankshaft key. Remove felt packing from nose of front cover. Clean area around seal.
3. Remove seal retaining snap ring. Using Seal Remover/Installer (6429), remove seal from compressor.

1. Lubricate shaft seal with refrigerant oil. Install Seal Protector (6231) over compressor shaft. Using flat end of Seal Remover/Installer (6429), install shaft seal until seal seats in housing.
2. Install NEW seal retaining snap ring. Install clutch assembly. Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Perform leak test.

CLUTCH ASSEMBLY

Note. Remove compressor if clearance is not adequate for clutch assembly removal.

1. Using Spanner (1014) on 10P13 or (T81P-19623-MH) on 10P15, 10P15C and 10P15F, hold clutch plate and remove crankshaft nut. Using Clutch Plate Remover (T80L-19703-B), pull clutch plate from compressor. Remove clutch plate shims.
2. Remove snap ring and clutch pulley assembly. If pulley assembly cannot be removed by hand, use Shaft Protector (T80L-19703-G) and 3-jaw puller. Remove snap ring. Disconnect electrical wiring, and remove clutch coil.

Scheme 3

1. Install clutch coil over locating pin, and install snap ring. Connect electrical wiring.
2. Install pulley assembly using Pulley Installer (T80L-19703-J) and hammer (if necessary). Install snap ring with beveled side out. Install clutch plate shims.
3. Ensure clutch plate aligns with crankshaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch plate. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools.
4. Using feeler gauge, check clearance between clutch plate and pulley. Rotate compressor clutch, and check clearance in more than one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not as specified, add or remove shims to correct clearance.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove compressor. Drain oil from compressor, and measure drained amount.
2. Mount compressor in vise clamping on mounting ears. Remove clutch plate and clutch plate shims.
3. Clean compressor front hub area. Remove felt packing and dust seal retainer from inside compressor nose. (Scheme 3) Using Shaft Key Remover (T81P-19623-NH), remove key from shaft.
4. Remove seal seat retaining snap ring. Clean inner bore of compressor nose. Using Shaft Seat Remover/Installer (T87P-19623-B), remove seal seat.
5. Using Shaft Seal Remover/Installer (T87P-19623-AH), remove seal by pushing downward on shaft seal remover/installer and rotating clockwise to engage seal tangs. Pull seal from compressor.

1. Place Shaft Seal Protector (T71P-19703-H) over compressor shaft. Lubricate shaft seal and nose of compressor with new refrigerant oil. DO NOT touch sealing surface of seal or shaft. Engage seal tangs on shaft seal remover/installer.
2. Align flats of seal with flats on crankshaft, and push new seal onto compressor shaft. Push downward on shaft seal remover/installer and turn counterclockwise to disengage seal tangs.
3. Attach shaft seal seat to shaft seal seat remover/installer, and lubricate seal seat with new refrigerant oil. Install seal seat and push inward against seal. Install seal seat retaining snap ring.
4. Install dust seal retainer and felt packing. Install clutch plate. Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Rotate compressor 10 revolutions to distribute oil. Install compressor. Evacuate and recharge system. Perform leak test.

1. Hold pulley assembly with Strap Wrench (D85L-6000-A). Apply battery voltage to clutch coil assembly, and remove crankshaft nut. Screw Clutch Plate Remover (T88C-19703-BH) into clutch plate, and remove clutch plate from compressor. Remove clutch plate shims.
2. Remove snap ring and clutch pulley assembly. Using a plastic hammer, tap pulley from shaft. Remove snap ring. Disconnect electrical wiring, and remove clutch coil.

1. Install clutch coil over locating pin, and install snap ring. Connect electrical wiring. Install pulley.
2. Ensure pulley bearing aligns with compressor head. Gently tap pulley on shaft with plastic hammer (if necessary). Install pulley retaining snap ring.
3. Install shims and clutch plate. Install crankshaft nut and tighten it to 10-12 ft. lbs. (14-16 N.m). DO NOT tighten nut with air tools. Using feeler gauge, measure clearance between clutch plate and pulley in several different areas. Proper clearance is .016-.028" (.41-.71 mm). If clearance is not as specified, add or remove shims to obtain proper clearance.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove compressor. Drain oil from compressor, and measure drained amount. Remove clutch assembly.
2. Remove manifold assembly from top of compressor. Clean compressor front hub area. Using Ring Remover (T71P-19703-C), remove retaining ring from front of compressor shaft.
3. Remove felt seal from front of compressor. Remove front head retaining bolts and front head from compressor. Remove snap ring from rear of front head. Remove seal from rear of front head.

1. Install seal and snap ring in front head. Install front head on compressor. Tighten bolts to 18-20 ft. lbs. (24-27 N.m). Install felt packing and retaining ring.
2. Install manifold assembly and tighten bolts to 18-20 ft. lbs. (24-27 N.m). Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Rotate compressor 10 revolutions to distribute oil in compressor. Install compressor. Evacuate and recharge system. Perform leak test.

Removal (Chrysler, Ford & General Motors)

1. Remove compressor shaft bolt and discard it. Remove clutch plate and shims. Tap on clutch plate using a soft-faced hammer (if necessary).
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring, and disconnect clutch coil electrical wiring. Remove clutch coil.

Installation (Chrysler)

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring with beveled side away from compressor.
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 .10" (2.5 mm). Install clutch plate and hold it tightly against shims.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface. On Laser and Talon, clearance should be .014-.026" (.36-.66 mm). On all other models, ensure clearance is .020-.035" (.51-.89 mm). Adjust shim thickness to obtain correct clearance. Install NEW compressor shaft bolt and tighten it to 13 ft. lbs. (18 N.m).
5. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

Note. After installing new clutch, ensure voltage is correct. Cycle clutch on for 5 seconds and off for 5 seconds. Repeat cycle 20 times with A/C on, blower fan on high speed and engine speed at 1500-2000 RPM.

Installation (Ford & General Motors)

1. Align clutch coil pin in back of coil with hole in front housing, and install clutch coil. Install snap ring with beveled side away from compressor.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. Coat splines of compressor shaft with White grease. If reusing original clutch plate and pulley, old shims can be used.
3. If installing new components, install one thin shim. Install clutch plate. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT use air tools to tighten bolt.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.36-.66 mm). Adjust shim thickness to obtain correct clearance.
5. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove compressor. Drain oil from compressor, and measure the amount drained. Remove clutch assembly. (Scheme 4)
2. Remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap ring. Position front head (nose up) on cardboard placed on a flat surface. Using brass drift, press shaft seal from front head.

Scheme 4

1. Lubricate new shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Press seal into front head, and install snap ring. Install felt dust seal and dust seal retainer.
2. Lubricate Shaft Seal Protector (J-34614) and front head "O" ring with refrigerant oil. Install shaft seal protector on crankshaft. Install a new front head "O" ring on cylinder assembly.
3. Install front head on cylinder assembly. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector.
4. Install through bolts with NEW brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m).
5. Using INCH lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 26 INCH lbs. (3 N.m). Install clutch assembly.
6. Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Perform leak test.

1. Hold clutch using Clutch Holder (J-33027-A). Remove compressor shaft bolt. Remove clutch plate and shims.
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring, and disconnect clutch coil electrical wiring. Remove clutch coil.

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring.
2. Install pulley assembly and snap ring. Install clutch plate and shims. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT use air tools to tighten bolt.
3. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .004-.008" (.10-.20 mm). Adjust shim thickness to obtain correct clearance.
4. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove clutch assembly. Remove front head retaining bolts. Separate front head and "O" ring from compressor. (Scheme 4)
3. Remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap ring. Press seal from front head.

1. Lubricate new shaft seal and seal cavity of front head with refrigerant oil. Press seal into front head, and install snap ring.
2. Lubricate front head "O" ring with refrigerant oil. Install front head "O" ring on cylinder assembly. Install Shaft Protector (J-34614) on compressor shaft. Install front head on cylinder assembly. Ensure dowel pins align.
3. Install all through bolts with NEW washers. Tighten through bolts to 18 ft. lbs. (24 N.m). Remove shaft protector. Install felt dust seal and dust seal retainer.
4. Using INCH-pound torque wrench, check compressor shaft rotating torque. Rotating torque should be 26 INCH lbs. (3 N.m). Install clutch assembly. Using new refrigerant oil, add to the compressor the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Perform leak test.