HVAC System - Compressor Servicing: Removal & Installation Ford Econoline E350

Removal

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Using a spanner wrench or clutch holder, remove clutch plate bolt. Discard bolt. Thread an 8-mm bolt into clutch plate, and remove clutch plate and shims.
2. Remove snap ring. Remove pulley assembly. (Scheme 1) Disconnect clutch coil lead. Install Shaft Protector (T89P-19623-FH) over compressor shaft.
3. Install 2-jaw puller on compressor. Tighten puller to remove clutch coil from compressor. DO NOT use air-powered tools when removing clutch coil.

Note. After installing a new clutch assembly, cycle clutch assembly 10 times with engine at idle to burnish clutch and prevent slippage.

Installation

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-powered tools when installing clutch coil. Ensure clutch coil seats against compressor head at all contact points of mounting surface.
4. Install pulley and snap ring. Install snap ring with beveled side away from compressor. Install shims and clutch plate. Install NEW clutch plate 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 .014-.033" (.36-.84 mm). If clearance is not as specified, add or remove shims to obtain proper clearance.

Scheme 1

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Using a spanner wrench or clutch holder, remove clutch plate bolt. Discard bolt. Thread an 8-mm bolt into clutch plate and remove clutch plate and shims.
2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Using Snap Ring Remover (T89P-19623-DH), rotate eye of snap ring. Pull up snap ring while holding snap ring at an 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. Lubricate shaft seal protector and shaft seal with refrigerant oil. Replacement Seal Kit (19D665) includes Shaft Seal Protector (T89P-19623-CH).
2. Coat shaft seal and protector with clean refrigerant oil. Install shaft seal on shaft seal protector 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 snap ring. Rotate compressor shaft about 10 revolutions and leak test shaft seal installation.
4. Install NEW shaft seal felt. Install clutch plate. Install new clutch plate 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.

1. Using spanner (1014), hold clutch plate and remove compressor shaft 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.
3. Disconnect clutch coil lead, and remove clutch coil.

1. Install clutch coil over locating pin, and install snap ring. Connect clutch coil lead.
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 compressor shaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch plate. Install compressor shaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (14-19 N.m). DO NOT tighten nut using air-powered tools.
4. Using feeler gauge, check clearance between clutch plate and pulley. Rotate compressor clutch, and check clearance in more than only one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not as specified, add or remove shims to correct clearance.

Scheme 2

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure drained amount.
2. Mount compressor in vise, clamping it by mounting ears. Remove clutch assembly and clutch plate shims. Remove front head from cylinder assembly.
3. Clean compressor front hub area. Remove felt packing and dust seal retainer from inside compressor nose. Using shaft seat Remover/Installer (T87P-19623-BH), Remove seal seat.
4. 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 compressor shaft, and push new seal onto compressor shaft. Push downward on shaft seal remover/Installer, and turn it 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 shaft sealseat snap ring.
4. Install dust seal retainer and felt packing. Install clutch plate. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Rotate compressor 10 revolutions to distribute oil. Install compressor. Evacuate and recharge system. Perform leak test.

Removal & Installation

1. Remove Allen head bolt from clutch hub. Remove clutch hub. Using snap ring pliers, remove clutch pulley snap ring. Remove clutch pulley from compressor shaft. (Scheme 3)
2. Disconnect clutch coil lead. Release lead from safety clip (if equipped). Using Phillips screwdriver, remove clutch coil screws. Remove clutch coil. To install, reverse removal procedure. Tighten clutch hub bolt to 10 ft. lbs. (14 N.m).

1. Remove compressor clutch assembly. Using scribe or small screwdriver, remove compressor shaft felt dust seal. Remove shaft seal snap ring.
2. Using Remover/Installer (T92C-19623-AH), remove compressor shaft seat. Using Remover/Installer (T92C-19623-BH), carefully remove compressor shaft seal. Inspect compressor shaft for damage. Repair or replace compressor as necessary. To install, reverse removal procedure.

Scheme 3

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Using a spanner wrench, hold clutch and remove compressor shaft nut. Using a steering wheel puller, remove clutch plate. Remove internal bearing dust cover and internal bearing snap ring. Remove key from compressor shaft.
3. Remove external front housing snap ring. Install jaws of puller in snap ring groove on pulley. Install puller plate on jaws. Thread 2 bolts through puller plate into jaws and finger tighten. Tighten pulley center bolt and remove pulley from compressor. Remove clutch coil snap ring and clutch coil.

1. Install clutch coil and clutch coil snap ring on compressor. Support compressor on rear mounting ears.
2. Using hammer, Handle (J-29886) and Driver (J-38467), install pulley assembly. Ensure driver rests on inner race of bearing when installing pulley assembly. Install external snap ring.
3. Install original shims. Use a hammer and Shaft Protector (J-29640) to install clutch plate on compressor shaft. Tighten compressor shaft nut to 10 ft. lbs. (14 N.m).
4. Using feeler gauge, measure clearance between clutch plate and pulley assembly in several areas. Clearance should be .016-.031" (.41-.79 mm). If clearance is not within specification, 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 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 4)

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 clearance between clutch plate and rotor assembly at more than one place. Proper clearance should be .016-.026" (.41-.66 mm). If clearance is not within specification, add or remove shims to obtain correct clearance. Install pulley assembly.
4. 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.

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 4)
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 4)
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 clearance between clutch plate and rotor assembly at more than one place. Proper clearance should be.016-.026" (.41-.66 mm). If clearance is not within specification, add or remove shims to obtain correct clearance. Install pulley 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 4

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 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 .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. Proper clearance is .013-.025" (.33-.64 mm). Adjust shim thickness to obtain correct clearance. Tighten compressor shaft nut to 13 ft. lbs. (18 N.m).
5. Once compressor shaft nut is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary. Install compressor.
6. Evacuate and charge system. Break-in compressor clutch assembly by engaging and disengaging clutch 20 times with engine at 1500-2000 RPM. Perform leak test.