Compressor Clutch: Service and Repair

The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle.

REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Remove the serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Remove the four bolts that secure the compressor to the mounting bracket.
5. Remove the compressor from the mounting bracket. Support the compressor in the engine compartment while servicing the clutch.

Clutch Nut Remove:

6. Insert the two pins of the spanner wrench (Special Tool C-4489) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut.

Clutch Plate Remove:

7. Remove the clutch plate with a puller (Special Tool C-6461).
8. Remove the compressor shaft key and the clutch shims.

External Snap Ring Remove:

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

Shaft Protector And Puller:

10. Install the lip of the rotor puller (Special Tool C-6141-1) into the snap ring groove exposed in the previous step, and install the shaft protector (Special Tool C-6141-2).

Install Puller Plate:

11. Install the puller through-bolts (Special Tool 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.

Clutch Coil Lead Wire Harness:

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

Clutch Field Coil Snap Ring Remove:

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

INSPECTION
Examine the friction surfaces of the clutch pulley and the front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring.

If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. Remove the felt from the front cover If the felt is saturated with oil, the shaft seal is leaking and the compressor must be replaced.

Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required.

CAUTION: The pulley and clutch plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact are(a)

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

Clutch Pulley Install:

4. Install the pulley bearing assembly with the installer (Special Tool C-6871). Thread the installer on the shaft, then turn the nut until the pulley assembly is seated.
5. Install the external front snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove.

CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.

6. Install the compressor shaft key and the original clutch shims on the compressor shaft.

Clutch Plate Driver:

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

Check Clutch Air Gap:

8. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.41 to 0.79 millimeter (0.016 to 0.031 inch). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation.

NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch.

9. Reverse the remaining removal procedures to complete the installation.

Clutch Break-In
After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the heater-A/C control to the Recirculation Mode, the blower motor switch in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.