A/C - Compressor Failure
TSB 07-18-309/17/07
A/C COMPRESSOR FAILURE
FORD:
2007-2008 Expedition
LINCOLN:
2007-2008 Navigator
ISSUE
Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed.
WITH ROTUNDA A/C FLUSH AND PURGE MACHINE:
1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00:
Climate Control System - General Procedures.
2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine.
3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor.
4. Remove and replace the A/C discharge and muffler line from the system.
5. Remove the condenser from the vehicle.
6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard.
7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present.
8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine.
9. Remove the original plug and snap-ring and discard.
10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle.
NOTE
IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY.
11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place.
12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes.
13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle.
14. Remove the rear TXV and discard if equipped.
15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes.
16. Install a new rear TXV.
17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle.
18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator.
19. Reconnect all A/C fittings.
20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated).
21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port.
^ 22 oz. - Front A/C
^ 33 oz. - With Auxiliary A/C
22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes.
A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE:
1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures.
2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle.
3. Remove and replace the discharge line.
4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place.
5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard.
6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser.
7. Remove the right front headlamp assembly per the WSM, Section 417-01.
8. Disconnect the lower (liquid) line connection to the condenser.
9. Pull the liquid line slightly forward so it will clear the condenser.
10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser.
11. Charge the system with the correct amount of R134a.
^ 22 oz. - Front A/C
^ 33 oz. - With Auxiliary A/C
12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature.
13. Recover the R134a in the system.
14. Remove the condenser.
15. Remove the original desiccant cartridge plug and 0-rings and discard.
16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap.
NOTE
IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY.
17. Install the condenser
18. Install the headlamp assembly per WSM, Section 417-01.
19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM.
^ 22 oz. - Front A/C
^ 33 oz. - With Auxiliary A/C
NOTE
COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MTO71803 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor
Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
19C836 42
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