All vehicles

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
If flushing of the refrigerant system has not been carried out, recover the refrigerant. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .
Remove the drive belt from the A/C compressor pulley.
6.0L diesel vehicles
Remove the cooling fan stator assembly. Refer to ENGINE COOLING .
4x2 vehicles and 4x4 Excursion vehicles
Remove the RH fender splash shield. Refer to FRONT END BODY PANELS .
All vehicles
Loosen the bolt and detach the compressor manifold and tube from the A/C compressor.
- Discard the O-ring seals.
  
  Fig 1: Removing Bolt And Compressor Manifold And Tube With Torque Specifications
  Courtesy of FORD MOTOR CO.
Disconnect the field coil electrical connector.

Fig 2: Disconnecting Field Coil Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nut and the battery cable bracket.

Fig 3: Removing Nut And Battery Cable Bracket With Torque Specifications
Courtesy of FORD MOTOR CO.
Remove the ground cable and the ground stud.

Fig 4: Removing Ground Cable And Ground Stud With Torque Specifications
Courtesy of FORD MOTOR CO.

NOTE: The lower rear bolt must be removed with the A/C compressor.

Fig 5: Removing Bolts And A/C Compressor With Torque Specifications

Courtesy of FORD MOTOR CO.

Remove the bolts and the A/C compressor.
To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. Refer to CLUTCH AND CLUTCH FIELD COIL .
- Install new O-ring seals.
- If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .
If filtering of the refrigerant system is not to be carried out, evacuate, leak-test and charge the refrigerant system. For additional information refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .