Compressor Clutch: Service and Repair

REMOVAL

NOTE: Refrigerant does not have to be reclaimed for compressor clutch, pulley or coil replacement. The compressor clutch can be serviced in the vehicle.

1. Disconnect and isolate negative battery cable.
2. Remove serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Remove three compressor mounting bolts.
5. Remove compressor from mounting bracket and support compressor while servicing the clutch.

Fig.1 Clutch Nut:

6. Insert two pins of the Spanner Wrench C-4489 into the holes of the clutch plate. Hold the clutch plate stationary and remove nut.

Fig.2 Clutch Plate:

7. Remove clutch plate with a Puller C-6461.
8. Remove compressor clutch shims.

Fig.3 External Snap Ring:

9. Remove external front housing snap ring with snap ring pliers.

Fig.4 Shaft Protector And Puller:

10. Install lip of the Rotor Puller C-6141-1 into the external snap ring groove and install Shaft Protector C-6141-2.

Fig.5 Puller Plate:

11. Install Puller Bolts C-6461 through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free.

Fig.6 Clutch Coil Lead Wire Harness:

12. Remove screw and retainer from clutch coil wire harness on the front of the compressor.

Fig.7 Clutch Field Coil Snap Ring:

13. Remove snap ring from compressor hub and remove clutch field coil. Slide clutch field coil off of the compressor hub.

INSTALLATION
1. Install clutch field coil and snap ring.
2. Install clutch coil wire harness retaining clip on the front of the compressor and tighten the screw.
3. Align rotor assembly squarely on the front compressor housing hub.

Fig.8 Clutch Pulley Install:

4. Install pulley bearing assembly with Installer C-6871. Thread installer on the shaft, then turn the nut until the pulley assembly is seated.
5. Install external snap ring with the bevel side of the snap ring facing outward. Verify snap ring is seated.

CAUTION: If snap ring is not seated in the groove it will vibrate out and cause clutch failure and severe compressor damage will occur.

6. Install compressor with the original clutch shims on the compressor shaft.

Fig.9 Clutch Plate Driver:

7. Install clutch plate with Driver C-6463. Install the shaft nut and tighten to 14.4 Nm (10.5 ft. lbs.).

Fig.10 Check Clutch Air Gap:

8. Check clutch air gap with a feeler gauge. If air gap does not meet specification 0.41-0.79 mm (0.016 - 0.031 in.) add or subtract shims as required.

NOTE:
- If air gap is not consistent around the clutch, lightly pry up at the minimum variations and lightly tap down at the maximum variation point.
- When installing a new clutch onto a compressor that previously did not have a clutch, use the shims 1.0, 0.50, and 0.13 mm (0.040, 0.020, and 0.005 in.) provided with the new clutch.

9. Position compressor on the mounting bracket and install bolts. Tighten bolts to 41 Nm (30 ft. lbs.).
10. Plug in compressor clutch harness.
11. Install serpentine drive belt.
12. Install Negative battery cable.
13. Start engine, set system to A/C mode, run engine at 1500-2000 rpm, and blower speed on high. Cycle the new A/C clutch 20 times (5 seconds ON and 5 seconds OFF).

NOTE: This procedure will seat (burnishing) friction surfaces and provide a higher clutch torque capability. This is only necessary on a NEW clutch.