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Old 01-17-2009, 02:28 PM   #1 (permalink)
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I'm a newbie here. Just found this forum and it has a lot of great info.
I need to swap my a/c compressor clutch assembly including the pulley and coil.
I got in there but for the life of me I can't figure out how to do it without taking the compressor out.
I'd like to avoid that if possible so that I don't have to get the system vacuumed and recharged.
Do you know where I can find directions? Thanks.
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Old 01-17-2009, 02:35 PM   #2 (permalink)
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I'm on to the same problem. Let me know if you figure it out.
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Old 01-17-2009, 03:11 PM   #3 (permalink)
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Remove the Negative battery cable.
Raise the car and support the car on jack stands. Just to the rear of the rear sub-frame mounts there are"rails" under the car, put the stands there as you will be dropping the sub-frame.
Disconnect the dog bone dampener.
Remove the serpentine belt.
Remove the right front wheel/tire assembly.
Disconnect the right side end link from either end, complete removal is NOT necessary.
Remove the right side strut pinch bolt.
Remove the little bolt that holds the brake line to the strut. 10mm I believe.
Place your jack under the passenger's side of the sub-frame near the control arm.
Remove the two sub-frame bolts on that side.
Lower the jack, slowly, to a position that you can see the A/C clutch.
It may be necessary to remove the front sub-frame bolt on the driver's side, but the last 3 vehicles I've done it wasn't necessary.
After you've got the cradle dropped, you should see the center bolt for the clutch. 8mm IIRC. Remove it and the front plate should come off with a little help of a screw driver and wiggling it a bit.
Behind that there is a snap ring, you'll need snap ring pliers to get it off, then you can remove the pulley. The last part is the coil, unplug it carefully, as I've seen people yank out the wire and mess up the plug. Then with a small hammer or a couple of screwdrivers, either pry the coil off, or knock it off by hitting it on two different sides alternately.
To reinstall the coil, you'll need a piece of 2x4 or something to cover the "face" of the coil to knock(press) it back on. From there install everything in reverse order that it came off.

You shouldn't need to realign the car, at least none of the ones I've done haven't needed it, but it would be a good idea to have it realigned if it has not been done with in a year.

Good luck, Rudy.
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Old 01-17-2009, 05:14 PM   #4 (permalink)
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Great write-up, thanks!
If instead you need to change the whole compressor, I am assuming it's easier to get to it from the top, just take the alternator out and move the p/s pump out of the way, right?
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Old 01-17-2009, 06:16 PM   #5 (permalink)
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Honestly, after you've done all that, it's a lot easier to get from the bottom, you'll see.
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Old 01-17-2009, 10:50 PM   #6 (permalink)
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Thanks rudedog.
I remember reading about having to set up some shims to keep the gap between the hub and the pulley. Is there a specific procedure for that?
As soon as we get a day above 32 degrees I am going to tackle this.
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Old 01-18-2009, 11:52 AM   #7 (permalink)
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Basically if there was a shim in the old unit use it first. Torque the center bolt, then measure the gap in three places around the circumference of the unit. If it's too little or too large, then grab another shim. Do this till you get the needed gap. ***Shims should come with the new clutch face if they don't you'll definitely need to get them.***
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Old 01-18-2009, 07:53 PM   #8 (permalink)
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any specific gap value or a way of telling if it's right? I would not want to go ahead and put everything back together just to find out that gap is wrong. I'm trying to get my hands on a Chilton and see it they specify it.
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Old 01-31-2009, 06:43 PM   #9 (permalink)
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alright guys...I am here with my chilton and unfortunately there is no mention of the gap. I am tackling this tomorrow. The motorcraft hub came with no shims. Is there a specific value for the gap between the hub and the pulley? I just don't want to go thru putting everything back together just to find out I screwed it up.
Can I just bolt the hub on the pulley with nothing inbetween?
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Old 01-31-2009, 06:53 PM   #10 (permalink)
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Magnetic Clutch
Air gap between pulley and clutch plate 0.35-0.75 mm (0.014-0.030 in)
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