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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. 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. Install the A/C clutch field coil.
  4. Install the A/C clutch field coil snap ring.
  5. Install the A/C clutch field coil electrical connector clip screw.
    Fig 1: Locating A/C Clutch Field Coil Electrical Connector Clip Screw
    G04682590Courtesy of FORD MOTOR CO.
    6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation.
  6. Install the A/C clutch pulley.
  7. Install the A/C clutch pulley snap ring.
  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 assembly.
  10. 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 14 Nm (10 lb-ft).
    Fig 2: Identifying Special Tool And A/C Clutch Disc And Hub Bolt
    G04682591Courtesy of FORD MOTOR CO.
  11. Install the A/C clutch shield and the 3 screws.
    Fig 3: Locating A/C Clutch Shield Screw
    G04682592Courtesy of FORD MOTOR CO.
  12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
    Fig 4: Measuring Clutch Air Gap
    G04682593Courtesy of FORD MOTOR CO.
  13. Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 2.3L  or AIR CONDITIONING (A/C) COMPRESSOR - 3.0L .
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