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Clutch and Clutch Field Coil: Installation

WARNING: This page is about a different car, the 2008 Mercury Sable, 2008 Ford Taurus X, and 2008 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
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 may 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. Install the A/C clutch field coil.
  4. Install the A/C clutch field coil snap ring with the bevel side up.
  5. Install the A/C clutch field coil electrical connector bracket screw.
    6. NOTE: To prevent air conditioning (A/C) compressor pulley damage, apply pressure to the inner bearing race only, or the inner and outer bearing races simultaneously.
    NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation.
  6. Install the A/C compressor pulley.
  7. Install the A/C compressor pulley snap ring with the bevel side out.
  8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
  9. Install the A/C clutch disc and hub.
  10. Using the Compressor Clutch Holding Tool, install the A/C compressor clutch disc and hub bolt.
    1. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool.
    2. Tighten to 14 Nm (124 lb-in).
    11. Fig 1: A/C Clutch Disc & Hub Bolt
    GF0004394Courtesy of FORD MOTOR CO.
  11. Measure and adjust the clutch air gap.
    • Measure the clutch air gap at 3 equally spaced locations around the A/C compressor pulley and calculate the average.
    • Adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
    12. Fig 2: Measuring Clutch Air Gap
    GF0004396Courtesy of FORD MOTOR CO.
  12. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor .
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