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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. 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/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.
  1. 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.
  2. Clean the A/C clutch field coil and pulley mounting surfaces.
    3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
  3. Install the A/C clutch field coil.
    1. Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned.
    2. Place the special tool on the A/C clutch field coil.
    3. Place the special tool 412-065 on the special tool 412-078.
    4. Use the special tool to install the A/C clutch field coil.
      Fig 1: Installing A/C Clutch Field Coil
      G04585238Courtesy of FORD MOTOR CO.
    4. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation.
  4. Install the A/C clutch pulley.
  5. Install the A/C clutch pulley snap ring with the bevel side out.
  6. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
  7. Install the A/C clutch disc and hub assembly.
  8. Install the A/C clutch disc and hub bolt.
    1. Hold the A/C clutch disc and hub with the special tool.
    2. Install the A/C clutch disc and hub bolt.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 2: Installing A/C Clutch Disc And Hub Bolt
      G04585239Courtesy of FORD MOTOR CO.
  9. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
    Fig 3: Measuring Clutch Air Gap
    G04585240Courtesy of FORD MOTOR CO.
  10. Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR .
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