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Clutch and Clutch Field Coil - Hybrid: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: NOTE: 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 new 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. Apply a pea-sized drop of silicone sealant to the thermal protection switch socket in the A/C compressor housing.
  4. Install the A/C clutch field coil.
    1. Install the A/C clutch field coil.
    2. Install the thermal protection switch and bracket.
    3. Tighten the thermal protection switch bolt to 6 Nm (53 lb-in).
    5. Fig 1: Thermal Limiter
    GF0018066Courtesy of FORD MOTOR CO.
    NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation.
  5. Install the A/C compressor pulley.
    1. Install the special tool.
    2. Install the A/C compressor pulley.
    6. Fig 2: A/C Compressor Pulley
    GF0012698Courtesy of FORD MOTOR CO.
  6. Install the A/C compressor pulley snap ring with the bevel side out.
  7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
  8. Install the A/C clutch disc and hub.
  9. Using the special tool, install the A/C compressor clutch disc and hub nut.
    1. Hold the A/C clutch disc and hub with the special tool.
    2. Tighten the nut to 26 Nm (19 lb-ft).
    10. Fig 3: A/C Clutch Disc & Hub Nut
    GF0012696Courtesy of FORD MOTOR CO.
  10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
    11. Fig 4: Checking Clutch Air Gap With Specification
    GF0012699Courtesy of FORD MOTOR CO.
  11. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - Hybrid  .
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