Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually as needed.

Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.
- Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
Install the A/C clutch field coil.
Install the A/C clutch field coil snap ring.
Install the A/C clutch pulley.
1. Install the special tool.
2. Install the A/C compressor.
  
  Fig 1: Installing A/C Compressor
  Courtesy of FORD MOTOR CO.
Install the A/C compressor pulley snap ring.
Install the A/C clutch hub spacer.
Install the A/C clutch disc and hub.
Install the A/C clutch disc and hub nut.
1. Using the special tool, hold the clutch disc and hub.
2. Install the nut.
  - Tighten to 20 Nm (15 lb-ft).
    
    Fig 2: Installing A/C Clutch Disc And Hub Nut
    Courtesy of FORD MOTOR CO.
Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.

Fig 3: Measuring Clutch Air Gap
Courtesy of FORD MOTOR CO.
Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 4.0L SOHC or AIR CONDITIONING (A/C) COMPRESSOR - 4.6L (2V) .