Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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.

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.
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 1: Installing A/C Clutch Field Coil Onto A/C Compressor

Courtesy of FORD MOTOR CO.

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

Fig 2: 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.

Install the A/C clutch pulley.
1. Install the special tool.
2. Install the pulley.
  
  Fig 3: Installing A/C Clutch Pulley
  Courtesy of FORD MOTOR CO.

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

Fig 4: 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 disc and hub spacer onto the A/C compressor shaft.

Fig 5: Installing One Nominal Thickness A/C Clutch Disc And Hub Spacer Onto A/C Compressor Shaft
Courtesy of FORD MOTOR CO.
Install the A/C clutch disc and hub.

Fig 6: Installing A/C Clutch Disc And Hub
Courtesy of FORD MOTOR CO.
Install the clutch disc and hub retaining nut.
1. Using the special tool, hold the A/C clutch disc and hub.
2. Tighten the nut.
  
  Fig 7: Installing Clutch Disc And Hub 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 disc and hub spacers.

Fig 8: Checking A/C Compressor Clutch Air Gap
Courtesy of FORD MOTOR CO.
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 .