Removal and Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 4.2L ENGINE , AIR CONDITIONING (A/C) COMPRESSOR - 4.6L, 5.4L, AND 6.8L ENGINES or AIR CONDITIONING (A/C) COMPRESSOR - 7.3L DIESEL ENGINE .
Remove the A/C clutch plate retaining nut.
1. Using the special tool, hold the A/C clutch plate.
2. Remove the nut.
  
  Fig 1: Removing A/C Clutch Plate Retaining Nut
  Courtesy of FORD MOTOR CO.
Remove the A/C clutch plate.

Fig 2: Removing A/C Clutch Plate
Courtesy of FORD MOTOR CO.
Remove the A/C clutch plate spacer.

Fig 3: Removing A/C Clutch Plate Spacer
Courtesy of FORD MOTOR CO.
Remove the A/C clutch pulley snap-ring.

Fig 4: Removing A/C Clutch Pulley Snap-Ring
Courtesy of FORD MOTOR CO.

CAUTION: Do not use air tools. Damage to the A/C clutch pulley may result.

Fig 5: Removing A/C Clutch Pulley

Courtesy of FORD MOTOR CO.

Using the special tool, remove the A/C clutch pulley.
Note the location of the A/C clutch field coil connector.
Remove the A/C clutch field coil snap-ring.

Fig 6: Removing A/C Clutch Field Coil Snap-Ring
Courtesy of FORD MOTOR CO.
Remove the A/C clutch field coil.

Fig 7: Removing A/C Clutch Field Coil
Courtesy of FORD MOTOR CO.
Clean the A/C compressor, A/C clutch field coil, and the A/C clutch pulley mounting surfaces.

CAUTION: There is an indexing locator on the A/C clutch field coil mounting surface. Make sure it is correctly aligned during installation to the A/C compressor.

Fig 8: Aligning And Installing A/C Clutch Field Coil To A/C Compressor

Courtesy of FORD MOTOR CO.

Align and install the A/C clutch field coil to the A/C compressor.
Install the A/C clutch field coil snap-ring.

Fig 9: Installing A/C Clutch Field Coil Snap-Ring
Courtesy of FORD MOTOR CO.

NOTE: The A/C clutch pulley fits tightly to the A/C compressor. It must be aligned correctly for installation.

Fig 10: Installing A/C Clutch Pulley

Courtesy of FORD MOTOR CO.

Install the A/C clutch pulley.

NOTE: The snap-ring must be installed with the bevel side up.

Fig 11: Installing A/C Clutch Pulley Snap-Ring With Bevel Side Up

Courtesy of FORD MOTOR CO.

Install the A/C clutch pulley snap-ring with the bevel side up.
Install one nominal thickness A/C clutch plate spacer onto the A/C compressor shaft.

Fig 12: Installing One Nominal Thickness A/C Clutch Plate Spacer Onto A/C Compressor Shaft
Courtesy of FORD MOTOR CO.
Install the A/C clutch plate.

Fig 13: Installing A/C Clutch Plate
Courtesy of FORD MOTOR CO.
Install the clutch plate retaining nut.
1. Using the special tool, hold the A/C clutch plate.
2. Tighten the nut.
  
  Fig 14: Installing Clutch Plate Retaining Nut
  Courtesy of FORD MOTOR CO.
Measure and adjust (if necessary) the A/C clutch air gap by removing or adding A/C clutch plate spacers.

Fig 15: Measuring And Adjusting A/C Clutch Air Gap
Courtesy of FORD MOTOR CO.
Install the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 4.2L ENGINE , AIR CONDITIONING (A/C) COMPRESSOR - 4.6L, 5.4L, AND 6.8L ENGINES or AIR CONDITIONING (A/C) COMPRESSOR - 7.3L DIESEL ENGINE .