Home ReviewsRefund
Home/Ford/Econoline/Ford Econoline I (1985-2013)/Repair manual/General Servicing - All Makes/HVAC System - Compressor Servicing
Contents Section: General Servicing - All Makes All sections

HVAC System - Compressor Servicing Ford Econoline I

General Servicing - All Makes 6 illustrations ~4339 words

Removal

  1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove A/C 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 pulley outside snap ring. Remove pulley assembly. (Scheme 1) Disconnect clutch coil lead. Install Shaft Protector (T89P-19623-FH) over compressor shaft. Install 2-jaw puller on compressor. Carefully tighten puller to remove clutch coil from compressor. DO NOT use air-powered tools when removing clutch coil.

Installation

  1. Ensure clutch coil mounting surface is clean. Install clutch coil. Ensure electrical connection is correctly positioned. Position Coil Replacer (T91L-19623-CH) onto coil and Coil Pressing Adapter (T89P-19623-EH) onto coil replacer.
  2. Install 2-jaw puller on compressor and coil replacer. Engage jaws on puller with compressor front mounts. Carefully tighten puller until clutch coil bottoms completely against compressor. DO NOT use air-powered tools when installing clutch coil.
  3. Carefully install pulley assembly onto compressor, ensuring that it is properly aligned. Install pulley assembly snap ring with beveled side out. Install shim(s) and clutch plate. Install a new clutch plate bolt, and tighten it to 98-123 INCH lbs. (11-14 N.m).
  4. Using a feeler gauge, measure air gap between clutch plate and pulley assembly mating surfaces in 3 places. Air gap should be 0.014-0.033" (0.36-0.84 mm). If air gap is not as specified, add or remove shims as necessary.

Scheme 1

Scheme 1
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. Using low pressure compressed air and a lint-free cloth, thoroughly clean seal inside and outside of compressor nose area. 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 (T94P-19623-F).
  2. Coat shaft seal and protector with clean refrigerant oil. Install shaft seal on shaft seal protector so lip of seal is toward large end of shaft seal protector. Install shaft seal protector onto compressor shaft.
  3. Using Shaft Seal Replacer (T89P-19623-AH), slowly push shaft seal down 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 98-123 INCH lbs. (11-14 N.m).
  5. Using a feeler gauge, measure air gap (in 3 places) between clutch plate and pulley assembly mating surface. Air gap should be 0.014-0.033" (0.36-0.84 mm). If air gap is not as specified, add or remove shims as necessary.

CLUTCH ASSEMBLY

CAUTIONDO NOT hammer on compressor shaft to remove clutch plate, as compressor damage will result.
  1. Remove compressor from vehicle. Place compressor in Holding Fixture (HD6/HT6 and HD6/HR-6HE compressor use J-33026; on V5 or V7 compressor use J-34992 or J-41790). On V5 or V7 compressor, remove dust cover (if equipped). Use Clutch Plate Spanner (J-33027-A) to hold clutch plate and remove compressor shaft nut using Shaft Nut Socket (J-33022). (Scheme 2)or (Scheme 3).
  2. On all compressors, using Clutch Plate Remover/Installer (J-33013-B), remove compressor clutch plate and hub. (Scheme 2)or (Scheme 3). Hold remover body and turn center screw into remover body to remove clutch plate and hub. Ensure forcing tip on remover/installer center screw is flat or end of shaft/axial plate will be damaged. Remove shaft key.
  3. Remove snap ring. Install Puller Guide (J-33023-A) on front head. Position Pulley and Bearing Puller (J-41552 for HD6/HT6 and HD6/HR-6HE or J-33020 for V5 or V7 compressor) into inner circle of slots on pulley assembly. Turn puller clockwise in slots. Tighten puller and remove pulley assembly.
  4. If bearing is to be removed, remove forcing screw from puller. With puller still engaged in pulley slots, invert assembly onto a solid flat surface. Use a hammer and Bearing Remover (J-9398-A) to drive bearing from pulley. (Scheme 2)or (Scheme 3). NOTE: It is not necessary to remove staking in front of bearing before removing bearing.
  5. Disconnect clutch coil lead. Scribe marks on compressor and clutch coil for installation reference. Remove clutch coil using Puller Adapter (J-33023-A) and 2-jaw puller.
  1. Align reference marks made during removal. Using Puller Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto compressor. Ensure clutch coil and installer stay lined up during installation. Using a 1/8" punch, stake clutch coil inner ring in 3 places, 120 degrees apart. Stake size should be 1/2 the area of punch tip and 0.010-0.015" (0.28-0.38 mm) deep. NOTE: To ensure proper bearing clearance, it is necessary to remove old stake metal before installing new bearing.
  2. To install pulley bearing, place pulley on Support (J-21352-A). DO NOT support pulley rim on flat surface, or pulley will be damaged. Install bearing in pulley using hammer, Bearing Installer (J-9481-A) and Handle (J-29886).
  3. With pulley on support, use Bearing Staking Guide (J-33019-1) and Bearing Staking Pin (J-33019-2) to stake pulley in 3 places, 120 degrees apart. Reposition pulley on support to ensure full support under staking pin. Metal stake should be similar to original stake (down to, but not touching bearing). Position pulley on compressor.
  4. Place Bearing Installer (J-33017) and Puller Guide (J-33023-A) over inner race of bearing. Using puller, press pulley onto compressor. Install snap ring. Install shaft key in clutch plate, allowing key to protrude about 1/8" from rear of clutch plate.
  5. Install clutch plate on compressor shaft. Using clutch plate remover/installer, press clutch plate onto compressor. Ensure shaft key is still in keyway before installing clutch assembly.
  6. Air gap between friction surfaces for HD6/HT6 and HD6/HR-6HE compressor is 0.020-0.030" (0.51-0.76 mm); for V5 and V7 compressor air gap is 0.015-0.020" (0.38-0.51 mm). On V5 and V7 compressor, using clutch plate spanner, install compressor shaft nut. Tighten shaft nut to 12.5 ft. lbs. (17 N.m). Check components for proper rotation.

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

SHAFT SEAL

Note. It is not necessary to replace shaft seal because of a small amount of oil found on adjacent surfaces. A small amount of oil is normal for lubrication purposes. Shaft seal should only be replaced after a confirmed refrigerant leak is found.

  1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Loosen and reposition compressor in mounting bracket. Remove clutch plate and hub assembly. See «CLUTCH ASSEMBLY»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing). (Scheme 2)or (Scheme 3).
  2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring. Ensure shaft and inside of compressor neck are clean and free of foreign material. Thoroughly clean "O" ring groove in front head.
  1. Install Shaft Seal Protector (J-34614) over compressor shaft. With shaft seal protector in place, lubricate "O" ring with refrigerant oil and install it on "O" Ring Installer (J-33011).
  2. Insert "O" ring installer in compressor until it bottoms. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring. Remove "O" ring installer.
  3. Lubricate shaft seal with refrigerant oil. Install shaft seal onto Seal Installer (J-23128-A). Install shaft seal so flared side of lip seal is installed toward compressor. Expand seal using shaft seal remover/installer. Install shaft seal on Seal Protector (J-34614). Place seal protector over shaft.
  4. Push shaft seal into compressor using a rotary motion until seal bottoms. Install new snap ring with flat side against seal. Install clutch plate and hub assembly onto compressor shaft. See «CLUTCH ASSEMBLY»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing) .

Removal & Installation (Metro, Firefly (Canadian) & Tracker)

  1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove A/C compressor. Drain, measure and discard refrigerant oil from compressor.
  2. Using Clutch Plate Holder/Remover (J-41384) remove clutch plate nut, washer and clutch plate from compressor drive shaft. Remove clutch pulley snap ring and shim. Using a plastic mallet, gently tap and remove clutch pulley. Remove clutch coil wire retainer from compressor. Remove clutch coil snap ring and clutch coil. (Scheme 4)
  3. Install clutch coil and snap ring. Attach clutch coil wire retainer to compressor. Install clutch pulley, snap ring and shim. Install clutch plate to compressor shaft. Measure air gap between clutch pulley and clutch plate.
  4. Air gap should be 0.014-0.026" (0.35-0.65 mm). Add or remove shims as necessary. Install compressor shaft nut and washer. Tighten compressor shaft nut to 11-15 ft. lbs. (15-20 N.m). After repairs, add NEW refrigerant oil to compressor equal to amount drained. To complete installation, reverse removal procedure.
  1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain, measure and discard refrigerant oil from compressor. Remove clutch plate, clutch pulley, shims, and clutch coil. See «CLUTCH ASSEMBLY»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing). (Scheme 4)
  2. Using a flat-blade screwdriver, remove felt ring and felt washer from front housing. Remove shaft key and shaft seal snap ring. Insert Compressor Shaft Seal Remover/Installer (J-33942-B) into seal. Turn seal remover/installer until contact with notches in seal is made. Remove shaft seal.
  1. Install Compressor Shaft Seal Protector (J-34614) onto compressor shaft. Lubricate NEW shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Engage seal remover/installer into seal notches and install seal onto compressor shaft. Remove seal protector and remover/installer.
  2. Install seal snap ring. Install felt washer and felt ring. Install clutch plate, clutch pulley, shims, and clutch coil. See «CLUTCH ASSEMBLY»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing). (Scheme 4) After repairs, add refrigerant oil to compressor equal to amount drained. To complete installation, reverse removal procedure. Perform leak test.

Scheme 4

Scheme 4
Scheme 4

Removal (Except Grand Cherokee)

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.

  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).

Note. On Grand Cherokee, compressor clutch can be serviced in vehicle without discharging A/C system.

Removal (Grand Cherokee)

Disconnect and isolate negative battery cable. Remove serpentine drive belt. Remove compressor shaft bolt. Using a plastic mallet, tap clutch plate to loosen from compressor shaft. Remove clutch plate, shaft key and shims. (Scheme 5) Remove snap ring, and remove pulley assembly. Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.

  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. Align snap ring eyelets to the left or right of clutch coil pin. Install rotor and pulley assembly. Install shims and snap ring. Install clutch hub.
  2. Hold clutch plate tight against shims and measure air gap between clutch plate and pulley face. Air gap should be 0.014-0.026" (0.35-0.65 mm). Add or remove shims as necessary. Install compressor shaft bolt. Tighten compressor shaft bolt to 115 INCH lbs. (13 N.m). To complete installation, reverse removal procedure.
  3. 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.

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 A/C compressor. Drain oil from compressor, and measure amount drained. Remove clutch hub, shims, rotor and pulley assembly, and clutch coil. See «CLUTCH ASSEMBLY»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing). (Scheme 5)
  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 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 an 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»(/ford/econoline/i-1985-2013/remont/general-servicing-all-makes/#hvac-system-compressor-servicing) .
  5. Using refrigerant oil, add same amount of oil to compressor as was drained from it. Install A/C compressor. Evacuate and charge system. Perform leak test.

Scheme 5

Scheme 5
Scheme 5

Ford Motor Co. (Taurus 3.4L SHO)

  1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove A/C compressor. Drain and measure oil from compressor.
  2. Remove pulley assembly. Using Spanner Wrench (T81P-19623-MH), remove shaft nut and lock washer. Using a steering wheel puller, remove clutch plate, shaft key and shim. Remove snap ring and pulley assembly, by hand. If necessary, use a 3-jaw puller to remove pulley assembly. Remove clutch coil wire from retaining brace on compressor. Remove snap ring and clutch coil. (Scheme 1)
  1. Install clutch coil. Ensure hole on back of clutch coil is aligned with pin on compressor head. Install snap ring with beveled side facing outward. Install clutch coil wire into retaining brace.
  2. Slip pulley assembly onto compressor shaft and install snap ring with beveled side facing outward. Install shim and shaft key. Align clutch plate with shaft key and install clutch plate. Use Hub Driven Plate Replacer (T80L-19703-F), if necessary. Using spanner wrench, install lock washer and shaft nut. Tighten shaft nut to 10-14 ft. lbs. (14-19 N.m).
  3. Using a feeler gauge, measure air gap between clutch plate and pulley assembly at 3 equally spaced locations. Rotate pulley 180 degrees and measure air gap at 3 locations again. Air gap should be 0.016-0.027" (0.41-0.69 mm). If air gap is not within specification, add or remove shims to obtain correct air gap.
  4. Add correct amount of refrigerant oil to compressor and install compressor. See COMPRESSOR REFRIGERANT OIL CHECKING. Evacuate and charge A/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 6)
  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. Add same amount of refrigerant oil to compressor as was drained from it. Install A/C compressor. Evacuate and charge A/C system. Perform leak test.

Scheme 6

Scheme 6
Scheme 6

SANDEN SD-7H15 7-CYLINDER

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

Removal (Cherokee, Dakota, Durango, Ram Pickup & Wrangler)

  1. Disconnect and isolate negative battery cable. Remove serpentine drive belt. Disconnect clutch coil harness connector. Without disconnecting refrigerant lines, remove A/C compressor from mounting bracket. Support compressor in engine compartment.
  2. Using spanner wrench, hold clutch plate and remove compressor shaft nut. (Scheme 1) 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 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 (Cherokee & Wrangler)

  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. Using Installer (C-6871), press pulley and bearing assembly onto compressor housing hub. Thread installer on compressor shaft and tighten nut until pulley assembly is seated.
  2. Install external front snap ring with beveled side facing outward. Ensure snap ring is properly seated. Install compressor shaft key and original shims. Using a plastic mallet and Driver (C-6463), install clutch plate on compressor shaft. Tighten compressor shaft nut to 10 ft. lbs. (14 N.m).
  3. Using feeler gauge, 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.

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 bottoms 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.

Removal (Ford "F" Series Super Duty Pickup)

  1. Disconnect and isolate negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect clutch coil harness connector and remove compressor. Drain oil from compressor, and measure amount drained.
  2. Using Spanner Wrench (T70P-4067-A), hold clutch plate and remove compressor shaft nut. (Scheme 1) If necessary, use a steering wheel puller to remove clutch plate and shim(s).
  3. Using a flat-blade screwdriver, remove pulley assembly bearing dust cover. Remove compressor shaft key and internal bearing snap ring. Remove external front housing snap ring.
  4. Install jaws of rotor puller into pulley assembly internal bearing snap ring groove. Install shaft protector over compressor shaft. Install puller flange plate on jaws. Install 2 puller bolts through puller flange plate into jaws and hand tighten. Tighten pulley center bolt clockwise and remove pulley assembly from compressor.
  5. Remove clutch coil wire harness retainer from compressor housing. Remove clutch coil snap ring and clutch coil.

Installation (Ford "F" Series Super Duty 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 pulley installer handle and driver 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.
  3. Install internal bearing and external front housing snap rings. Install original shim(s) and compressor shaft key. Using a hammer and shaft protector, install clutch plate on compressor shaft. Ensure clutch plate bottoms out on clutch shims. Replace compressor shaft nut and tighten compressor shaft nut to 25-30 ft. lbs. (34-41 N.m).
  4. Measure air gap between clutch plate and pulley assembly in 3 locations spaced equally around pulley. Rotate clutch pulley 180 degrees and check air gap as specified. 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. To complete installation, reverse removal procedure. Evacuate, charge, and leak test A/C system.
  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 A/C 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.

Note. Discharging A/C system and removing refrigerant lines from compressor is not necessary to service clutch assembly.

  1. Loosen tensioner and remove drive belt from pulley. Disconnect clutch electrical connector. Remove compressor mounting bolts. With refrigerant lines connected lift compressor upward and forward. Install one front mounting bolt through bottom rear compressor mounting ear. Tighten bolt so compressor is supported by mounting bracket.
  2. Using Clutch Drive Plate Holder (SA9510AC), remove clutch drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve (SA9506AC) into center of drive plate. Install remover bolt. While holding clutch remover sleeve, tighten remover bolt and remove drive plate and shims.
  3. Remove pulley external snap ring. Position Puller Center Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller to back of pulley. Tighten puller bolt against pulley center adapter and remove pulley. Remove clutch coil screws. Disconnect clutch coil wire. Remove clutch coil.
  1. Install coil in original position. Ensure electrical connector is aligned with indent in front of compressor head. Tighten screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC-3) and thrust bearing on installation bolt and insert through center of pulley. Finger-tighten pulley installation bolt into compressor shaft.
  2. Finger-tighten nut on installation bolt to align pulley to compressor. Hold end of bolt and tighten nut until pulley bottoms on compressor. Loosen nut and remove installation bolt, thrust bearing and drive plate installer. Install snap ring with tapered side out.
  3. Install thrust bearing on installation bolt and insert through clutch drive plate. Place original shims on installation bolt. Thread bolt into compressor shaft. Hold end of bolt and tighten nut until clutch drive plate bottoms out. Loosen nut and remove installation bolt and thrust bearing. Install center bolt and tighten to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
  4. Using a feeler gauge, measure air gap between drive plate and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap is not as specified, add or remove shims as necessary. Install compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs. (49 N.m) and rear bolts to 19 ft. lbs. (26 N.m). Connect clutch electrical connector and install accessory drive belt.
  5. Start engine and allow it to idle. Turn A/C on and cycle A/C compressor on and off 10-15 times to break-in clutch drive plate and pulley assembly.

See also:
• CLUTCH ASSEMBLY

More articles — HVAC