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Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system.
  • If A/C flushing equipment is available, carry out flushing of the air conditioning system prior to installing a new air conditioning compressor. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  • If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  • Install a new evaporator core orifice (19D990) as directed by the A/C flushing or filtering procedure.
  • Install a new suction accumulator (19C836) as directed by the A/C flushing or filtering procedure.
NOTE: If installing a new A/C compressor, the A/C clutch disc and hub (19D786), A/C compressor pulley (19D784) and A/C clutch field coil (19D798) must be inspected and transferred from the old unit to the new unit if suitable for reuse.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  3. Remove the accessory drive belt (8620) from the A/C compressor pulley.
  4. Remove the bolt.
    Fig 1: Removing Bolt
    G03890108Courtesy of FORD MOTOR CO.
    5. NOTE: The upper and lower rear compressor bolts must be removed with the A/C compressor.
    Fig 2: Removing A/C Compressor Mounting Bolts
    G03890109Courtesy of FORD MOTOR CO.
  5. Remove the A/C compressor mounting bolts.
  6. Disconnect the field coil electrical connector.
  7. Remove the RH front wheel and tire assembly.
  8. Loosen the bolt and detach the compressor manifold and tube.
    • Discard the O-ring seals.
      Fig 3: Loosening Bolt
      G03890110Courtesy of FORD MOTOR CO.
    9. NOTE: The A/C compressor must be removed from the bottom.
  9. Remove the A/C compressor.
  10. 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. For additional information, 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. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  11. 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 .
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