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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. 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 the pulley bearing mounting surfaces.
    3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
    Fig 1: Installing A/C Clutch Field Coil
    GF0008053Courtesy of FORD MOTOR CO.
  3. Install the A/C clutch field coil.
    • Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned.
    • Place the special tool on the A/C clutch field coil.
    • Place the special tool on the special tool.
    • Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor.
    4. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation.
    Fig 2: Locating A/C Clutch Pulley
    GF0008054Courtesy of FORD MOTOR CO.
  4. Install the A/C clutch pulley.
  5. Install the pulley snap ring with the bevel side out.
    Fig 3: Locating A/C Clutch Pulley Snap Ring
    GF0008055Courtesy of FORD MOTOR CO.
  6. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
    Fig 4: Locating A/C Clutch Hub Spacer
    GF0008021Courtesy of FORD MOTOR CO.
  7. Install the A/C clutch disc and hub.
    Fig 5: Locating A/C Clutch Disc And Hub
    GF0008022Courtesy of FORD MOTOR CO.
  8. Install the A/C clutch disc and hub retaining bolt.
    • Hold the A/C clutch disc and hub with the special tool.
    • Tighten the bolt to 13 Nm (10 lb-ft).
    Fig 6: Using Special Tool To Hold A/C Disc And Hub Assembly
    G03952015Courtesy of FORD MOTOR CO.
  9. Measure and adjust the clutch air gap by removing or adding the A/C clutch disc and hub spacer.
    Fig 7: Checking A/C Compressor Clutch Air Gap
    G03879165Courtesy of FORD MOTOR CO.
  10. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor  in this article.
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