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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. 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. Damage to the air conditioning (A/C) clutch field coil or A/C compressor may result.
  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 special tool 412-065 on special tool 412-078.
    4. Use the special tool to install the A/C clutch field coil.
    4. Fig 1: Installing A/C Clutch Field Coil Using Special Tools (412-001, 412-065, 412-078)
    GF0008053Courtesy of FORD MOTOR CO.
  4. Install the A/C compressor pulley.
  5. Install the A/C compressor pulley snap ring.
  6. Install the A/C clutch disc and hub spacer(s) and the A/C clutch disc and hub.
  7. Install the A/C clutch disc and hub bolt.
    1. Hold the A/C clutch disc and hub with the special tool.
    2. Tighten to 13 Nm (10 lb-ft).
    8. Fig 2: A/C Clutch Disc & Hub Bolt
    GF0004394Courtesy of FORD MOTOR CO.
  8. Measure and adjust the clutch air gap by adding or removing A/C clutch disc and hub spacers.
    9. Fig 3: Measuring Clutch Air Gap With Specification
    GF0004396Courtesy of FORD MOTOR CO.
  9. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 4.6L, 5.4L, and 6.8L  or Air Conditioning (A/C) Compressor - 6.0L Diesel .
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