Air Conditioning: Removal & Installation Ford Thunderbird XI

Removal and Installation

1. If A/C flushing equipment is available, carry out flushing of the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
2. If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
3. Install a new thermostatic expansion valve (19849) as directed by the A/C flushing or filtering procedure .
4. Install a new receiver/drier (19959) as directed by the A/C flushing or filtering procedure .

Note. If installing a new A/C compressor, the A/C clutch disc and hub (19D786), A/C compressor pulley (19D784) and A/C clutch field coil (19D798) must be inspected and transferred from the old unit to the new unit if suitable for reuse.

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1. Remove the air cleaner outlet tube. .
2. Rotate the drive belt tensioner and remove the drive belt from the A/C compressor pulley.
3. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
4. Remove the bolt and position aside the compressor manifold and tube assembly. Discard the O-ring seals.
5. Disconnect the field coil electrical connector.
6. Remove the two lower A/C compressor bolts.
7. Remove the A/C compressor. Remove the nut and position the power steering hose aside. Remove the two upper A/C compressor bolts. Remove the A/C compressor.
8. To install, reverse the removal procedure. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to «CLUTCH AND CLUTCH FIELD COIL»(ref-204570-S28463169362005111300000) . Install new O-rings lubricated in clean PAG oil. If filtering of the air conditioning system is not to be performed, correctly oil match the system with clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
9. If filtering of the refrigerant system is not to be performed, evacuate, leak-test, and charge the refrigerant system. For additional information refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .

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1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(ref-204570-S22375362492005111300000) .
2. Remove the A/C clutch. Hold the A/C clutch hub. Remove the nut. Remove the A/C disk and hub.
3. Remove the spacer.
4. Remove the pulley snap ring.
5. Using the special tool, remove the A/C clutch pulley.
6. Remove the sensor. Remove the bolt and the hold-down bracket. Lift out the sensor while lightly twisting and pulling up on the sensor. It may be necessary to pry up lightly with a small screwdriver.
7. Remove the field coil snap ring.
8. Remove the A/C clutch field coil.

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1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Install the A/C clutch field coil.
4. Install the snap ring with the bevel side out.
5. Using the special tool, install the clutch bearing and pulley. Position the clutch bearing and pulley. Install the special tool. If required, gently tap and install the clutch bearing and pulley.
6. Install the snap ring with the bevel side out.
7. Install the spacer.
8. Install the A/C clutch.
9. Install the sensor. Push the sensor into position. Install the bolt and the hold-down bracket.
10. Install the bolt. Hold the A/C clutch. Install the bolt.
11. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
12. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(ref-204570-S22375362492005111300000) .

Note. If an A/C evaporator core leak is suspected the A/C evaporator core must be leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .

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1. Remove the evaporator core housing. For additional information, refer to «HEATING & VENTILATION»(ref-204569) .
2. Remove the screws which connect the air inlet housing to the evaporator housing.
3. Disengage the clip and separate the housings.
4. Disconnect the evaporator core housing wire harness connectors and position the wire harness aside.
5. Remove the gasket.
6. Remove the nine screws, disengage the clip and separate the heater/evaporator core housing.
7. Remove the evaporator core.
8. Disconnect the fittings and remove the thermostatic expansion valve.
9. To install, reverse the removal procedure. Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. Add the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the new A/C evaporator core. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .

Note. If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .
2. Remove the air cleaner outlet tube. .
3. Remove the upper radiator sight shield.
4. Remove the nut and disconnect the condenser inlet fitting.
5. Remove the RH and LH upper condenser bracket pin-type retainers.
6. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
7. Remove the screws and remove the air deflector.
8. Remove the air deflector. Remove the pin-type retainers. Remove the side-clip retainers.
9. Remove the nut and disconnect the condenser outlet fitting.
10. Remove the LH bolt.
11. Remove the RH bolt and lower the condenser core.
12. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean PAG oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-204566) .