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HVAC System - Compressor Servicing: Removal & Installation Ford Explorer II

General Servicing - All Makes 1 illustration ~1020 words

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 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 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.
  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. Using NEW refrigerant oil, add correct amount of oil to compressor and install compressor. See COMPRESSOR REFRIGERANT OIL CHECKING. Evacuate and charge A/C system. Perform leak test.

Removal (Ford Motor Co.)

  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 thumb head through-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 Motor Co.)

  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 has bottomed 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.

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