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Old 01-20-2013, 11:20 AM   #1 (permalink)
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Default 2004 Taurus dohc ac compressor removal

Just finished an ac compressor removal and replacement on a 2004 Duratec. I ended up taking it out through the top unlike many articles I have read about taking it out the bottom. The compressor started making noise in the summer although the ac worked fine, I wasnt sure if it was the clutch or bearing and seemed to be intermittent. It finally gave up last weekend, so i guess it was time to do something, bearing seemed to be gone. After surveying the situation I thought I could get it out the top right side after removing the power steering hose. Lets just say after a few hours spent just removing the compressor bolts and then trying to take it out the way I thought it would come out I could see there was no way. Let me say the reason I started this job was to (A) save money by not taking it to the dealer (B make the car driveable asap. After reading about the horror stories of a $2000 bill at the dealer and just slightly less at an independant garage I'm thinking I have to do this job myself to be able to get the car back on the road and be able to eat next month !!. The taurus has 168,000 on it and and although it is in very good condition and well taken care of probably not worth much over $3800 so I couldn't justify 2 grand on repairs. Unfortunately it is not driveable without the compressor in place , no bypass pulleys or shorter belt routing options are available for this model and engine. I ended up getting a Ford service DVD off of ebay as suggested by some people, what a joke that was, very vague instructions! Some people suggested removing the exhaust pipe from the manifold down to the cat converter. heres how I removed the compressor.

A) Unhook battery from both terminals, remove serpentine belt from top pulley by pulling up and sliding off front (can be done without tools)
(b) block rear wheels and jack front of car and remove radiator deflector underneath the car and drain radiator.
C) release fuse block above left hand fan, remove both fans (1 bolt each)
D) remove 2 radiator hoses on top left side (1 goes to the water pump), (no need to remove top hose completely)
E) remove sensor from exhaust manifold
F) remove black painted coolant tube that runs in the front , above the exhaust manifold.
G) remove compressor manifold bolt at the rear of compressor
H) remove the four bolts holding the compressor
I) guide the compressor towards the left hand fan opening and up and out the top.
J) reverse the above when installing.
K) When reinstalling the sepentine belt it can be put back on without tools but you have to be strong!! Pull up on the belt and slide it over the top pulley, you may need help and watch your fingers!!

This a messy 8-10 hour job and will make your hands look like hamburger from cuts and scrapes. The bolts and such are difficult to get to and the stupid christmas tree wire holders are the worst inventions ever! They dont like to come out! I put a new compressor in from Autozone for $186 w/tax and some PAG46 oil in the compressor before I installed it (read the directions that comes with your compressor). I will not be filling the ac until sometime this spring so I pulled the ac clutch fuse in the engine compartment fuse box. I cant say this job is complete yet but it is back on the road for under $200 which was my main goal and I'm happy to say I only ended up with 1 part leftover! After finishing and picking up the tools I found a rubber bumper that the fan sits in on the lower mount, it must have stuck to the bottom of the fan then came off when i set it on the floor , oh well. Hope this post helps some of you!! Just remember this guide is just for reference and I'm not responsible for accidents or otherwise!!! LOL

Last edited by cpayton61; 01-20-2013 at 11:24 AM. Reason: steps forgotten
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Old 01-20-2013, 12:39 PM   #2 (permalink)
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Thanks for the write-up! Good job!
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