Compressor Clutch / Coil Assembly Replacement

Fig 13 Compressor Shaft Nut Removal/Installation:

NOTE: 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. On models with the diesel engine option, remove the compressor. Do not remove the refrigerant lines or fittings.
3. Insert the two pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut.

Fig 14 Clutch Puller -- Diesel Models:

4. Remove the clutch plate. On models with the diesel engine option, a puller (Special Tool 6461 in Kit 6460) is used to remove the clutch plate. This compressor also uses a shaft key which must be removed.

Fig 15 External Snap Ring Removal:

5. Remove the external front rotor snap ring with snap ring pliers.

Fig 16 Shaft Protector And Puller:

6. Install the lip of the rotor puller (Special Tool C-6141-1 in Kit 6460) into the snap ring groove exposed in the previous step, and install the shaft protector (Special Tool C-6141-2 in Kit 6460).

Fig 17 Install Puller Plate:

7. 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.

Fig 18 Clutch Coil Wire Harness:

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

Fig 19 Clutch Field Coil Snap Ring Removal:

9. Remove the snap ring from the compressor hub and remove the clutch field coil.

Fig 20 Rotor Installer Set:

INSTALLATION
1. Install the clutch field coil and snap ring.
2. Install the clutch coil wire harness retainer clip on the compressor front housing and tighten the retainer screw.
3. Align the rotor assembly squarely on the front compressor housing hub.
4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460).

Fig 21 Rotor Installation:

5. Place the driver tool assembly into the hearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor hearing inner race.
6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process to indicate the bottoming of the rotor.
7. Install the external front rotor snap ring.

Fig 22 Clutch Plate Installation:

8. Check that the original clutch shims are in place on the compressor shaft and install the clutch plate. On models with the diesel engine option, install the shaft key. On all models use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the clutch plate.
9. Replace the compressor shaft hex nut. Tighten the nut to 14.4 N.m (10.5 ft. lbs.).

Fig 23 Check Clutch Air Gap:

10. 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 specification is 0.41 to 0.79 mm (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 0.040 in, 0.020 in, and 0.005 in shims from the clutch hardware package that is provided with the new clutch.

11. 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 mode control switch in Recirculation (A/C) mode, the blower motor switch in the highest speed position, and the engine speed at 1,500 - 2,000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.