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A/C Compressor Clutch: Installation

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  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. Care must be taken not to pinch the lead wire with the retaining clip when tightening the retaining 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 1 ).
    Fig 1: Setting Rotor Installer
    G02655873Courtesy of DAIMLERCHRYSLER CORP.
  5. Place the driver tool assembly into the bearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor bearing inner race (Fig 2 ).
    Fig 2: Installing Rotor
    G02655874Courtesy of DAIMLERCHRYSLER CORP.
  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 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.
  8. Ensure that there is adequate clearance between the lead wire and clutch rotor.
  9. Install the original clutch shims on the compressor shaft.
  10. Install the clutch plate. Use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft (Fig 3 ). 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.
    Fig 3: Installing Clutch Plate
    G02655875Courtesy of DAIMLERCHRYSLER CORP.
  11. Replace the compressor shaft hex nut. Tighten the nut to 15 to 20 N.m (11 to 15 ft. lbs.).
  12. Check the clutch air gap with a feeler gauge (Fig 4 ). 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.
    Fig 4: Checking Clutch Air Gap Using Feeler Gauge
    G02655876Courtesy of DAIMLERCHRYSLER CORP.
  13. To complete the procedure, (Refer to INSTALLATION  .
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