Compressor Clutch Assembly

Remove or Disconnect

Tools Required:
J 38874 Drive Plate Holding Tool and Puller
J 8433 Heavy Duty Pulley Puller
J 38424 Pulley Puller Adapter
J 33025 Clutch Coil Puller Legs

1. Negative (-) battery cable.
2. Compressor from vehicle.
^ Mount compressor into vise.
^ Install a J 38874 to the drive plate.

Removing Drive Plate Retaining Bolt:

3. Drive plate retaining bolt. Use the J 38874 to hold the drive plate to ease retaining bolt removal.

Removing Drive Plate:

^ Install the drive plate puller to the J 38874 tool and remove the drive plate.

4. Drive plate shim(s).

Removing Snap Ring:

5. Snap ring retaining drive pulley with snap ring pliers.

Removing Drive Pulley:

^ Using a J 8433, J 33025 and a J 38424, remove drive pulley.

Removing Lead Wire Retaining Clip:

6. Lead wire retaining clip.
7. A/C compressor clutch electrical connector.

Removing Field Coil:

8. Three screws and field coil from compressor.

Inspect
1. Drive plate frictional surface for signs of damage due to excessive heat. If the drive plate is damaged, replace the entire magnetic clutch assembly.
2. Drive pulley frictional surface for excessive grooving due to slippage. If the drive pulley is damaged, replace the entire magnetic clutch assembly. Field coil for cracked insulation or a loose connection.
3. If the field coil is damaged, replace the entire magnetic clutch assembly.

Clean
^ Drive pulley frictional surface before installation.

Install or Connect

Tools Required:
J 38873 Drive Pulley Installer
J 38874 Drive Plate Holding Tool and Puller

Installing Field Coil:

1. Field coil to compressor. Align the notch on the field coil to the compressor.
2. Three screws securing field coil.

Tighten
^ Field coil retaining screws to 5 N.m (44 lb.in.).

3. A/C compressor clutch electrical connector.
4. Lead wire retaining clip.

Installing Drive Pulley:

5. Drive pulley using a J 38873.
6. Snap ring securing drive pulley.
7. Drive plate shim(s).

Installing Drive Plate:

8. Drive plate to drive pulley using the J 38873.

NOTICE: Make sure that the drive plate splines are properly aligned with the compressor drive shaft before drawing drive plate onto shaft.

^ Install a J 38874 to the drive pulley.

Installing Drive Plate Retaining Bolt:

9. Drive plate retaining bolt. Use the J 38874 to hold the drive plate stationary.

Tighten
^ Drive plate retaining bolt to 14 N.m (124 lb.in.).

Inspect
^ Drive pulley for proper rotation.

Measure

Measuring Drive Plate Clearance:

^ Drive plate-to-drive pulley clearance using a feeler gage (Figure 16). Standard clearance is 0.3 to 0.6 mm (0.01 to 0.02-inch). If clearance is less than 0.3 mm (0.01-inch), install adjusting shims as required to bring clearance into specification. Shims are available in 0.1 mm (0.0039-inch), 0.3 mm (0.01-inch) and 0.5 mm (0.0197-inch) sizes.

^ Remove compressor from vise.
10. Compressor to vehicle.
11. Negative (-) battery cable.

Tighten
^ Negative (-) battery cable-to-negative (-) battery terminal retainer to 15 N.m (11 lb.ft.).