Clutch and Clutch Field Coil - 2.5L, 3.0L (4V): Installation

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: A new A/C compressor may come equipped with a clutch and pulley. If not, the A/C clutch components should be reused unless obvious signs of damage are found.

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.
Clean the A/C clutch field coil and pulley mounting surfaces.
Install the A/C clutch field coil.
Install the 4 A/C clutch field coil screws.

NOTE: The Air Conditioning (A/C) compressor must be positioned on the press so that only the flat part of the A/C compressor housing is contacting the base with the A/C compressor shaft aligned with the center of the press shaft. If the A/C compressor is not installed correctly on the press, the A/C compressor and/or A/C compressor pulley will be damaged.

Install the A/C compressor pulley.
1. Install the A/C compressor on a suitable press.
2. Position the A/C compressor pulley on the A/C compressor.
3. Install the A/C Clutch Installer on the A/C compressor pulley.
4. Using the press, install the A/C compressor pulley.
  
  Fig 1: Installing A/C Compressor Pulley
  Courtesy of FORD MOTOR CO.
Install the A/C compressor pulley snap ring with the bevel side out.
Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
Install the A/C clutch disc and hub.
Install the A/C compressor clutch disc and hub bolt.
1. Hold the A/C clutch disc and hub with a suitable spanner-type wrench.
2. Tighten the bolt to 20 Nm (177 lb-in).
  
  Fig 2: Removing A/C Clutch Disc And Hub Bolt
  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: Checking A/C Clutch Air Gap Between Clutch Plate And A/C Clutch Pulley
Courtesy of FORD MOTOR CO.
Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 2.5L or AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (4V) .