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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: 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 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 disc and hub, A/C compressor pulley and A/C clutch field coil mounting surfaces.
  3. Apply a pea-sized drop of silicone sealant to the thermal limiter socket.
  4. Install the A/C clutch field coil.
    1. Install the A/C clutch field coil.
    2. Install the thermal limiter.
    3. Tighten to 6 N.m (53 lb-in).
    Fig 1: Installing A/C Clutch Field Coil
    G04658025Courtesy of FORD MOTOR CO.
  5. Install the A/C clutch field coil snap ring.
    6. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation.
    Fig 2: Installing A/C Compressor Pulley
    G04658026Courtesy of FORD MOTOR CO.
  6. Install the A/C compressor pulley.
    1. Install the special tool.
    2. Install the A/C compressor pulley.
  7. Install the A/C compressor pulley snap ring with the bevel side out.
  8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
  9. Install the A/C clutch disc and hub.
  10. Install the A/C clutch disc and hub nut.
    1. Hold the A/C clutch disc and hub with the special tool.
    2. Tighten to 26 N.m (19 lb-ft).
    Fig 3: Installing A/C Clutch Disc & Hub
    G04658027Courtesy of FORD MOTOR CO.
  11. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
    Fig 4: Measuring & Adjusting Clutch Air Gap
    G04658028Courtesy of FORD MOTOR CO.
  12. Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR .
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