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fordman312009, Ford Technician
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Experience:  all ford training done asset grad.
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2002 Ford Taurus: compressor..clutch..3.0l DOHC V-6

Resolved Question:

I want to replace the A/C compressor clutch on my 2002 Ford Taurus w/ 3.0l DOHC V-6 without evacuating the refridgent or having to disconect the refridgent lines. I am looking for the procedure to accomplish this.are you aware of a procedure
Submitted: 5 years ago.
Category: Ford
Expert:  fordman312009 replied 5 years ago.
if your just replacing the clutch just take off the 8mm bolt and remove the clutch but beware theres a spacer washer inside there ok and thats what you do reuse the washe and go from there ok
Customer: replied 5 years ago.

The compressor is still installed in the car I am looking for the procedure to remove the compressor clutch from the compressor without removing the refridgent lines and having to vacuum the system.

Expert:  fordman312009 replied 5 years ago.
ok this is the service book instructions and it says to remove the compressor but you should try what i said to try first then you wont have to evacuate the ac system




SECTION 412-03: Air Conditioning 2002 Taurus/Sable Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/23/2003

--------------------------------------------------------------------------------

Clutch and Clutch Field Coil

Special Tool(s) Remover, Compressor Pulley
412-001 (T71P-19703-B)
Installer, A/C Compressor Coil
412-065 (T89P-19623-EH)
Holding Fixture, Compressor Clutch
412-103 (T95L-19703-AH)
Installer, A/C Compressor Field Coil
412-078 (T91L-19623-CH)
Remover, A/C Compressor Field Coil
412-067 (T89P-19623-FH)

Removal

Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor — 3.0L (2V) or Air Conditioning (A/C) Compressor — 3.0L (4V) in this section.
Remove the A/C clutch hub retaining bolt.
Hold the A/C clutch hub with the special tool.
Remove the bolt.

Remove the A/C clutch disc and hub and the spacer (19D648).
Thread an 8 x 1.25 mm (0.04 in) bolt into the A/C clutch disc and hub to force it from the compressor shaft.
Lift the A/C clutch disc and hub and the spacer from the compressor shaft.

Remove the pulley snap ring.

Remove the A/C compressor pulley.
Install the special tool.
Remove the compressor pulley.

CAUTION: Do not use air tools. The A/C compressor clutch field coil can be easily damaged.

Remove the A/C compressor clutch field coil.
Install the special tool on the nose opening of the A/C compressor.
Install the special tool.
Remove the A/C compressor clutch field coil.

Installation

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 clutch field coil and pulley bearing mounting surfaces.
CAUTION: Do not use air tools. The A/C compressor clutch field coil can be easily damaged.

Install the A/C compressor clutch field coil.
Place the A/C compressor clutch field coil on the A/C compressor with the A/C compressor clutch field coil electrical connector correctly positioned.
Place the special tool on the A/C compressor clutch field coil.
Place the special tool on the special tool.
Use the special tool to install the A/C compressor clutch field coil until bottomed completely against the A/C compressor.

NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation.

Install the A/C clutch pulley.

Install the pulley snap ring with the bevel side out.

Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.

Install the A/C clutch.

Install the A/C clutch hub retaining bolt.
Hold the A/C clutch hub with the special tool.
Tighten the bolt.

Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.

Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor — 3.0L (2V) or Air Conditioning (A/C) Compressor — 3.0L (4V) in this section.

fordman312009, Ford Technician
Category: Ford
Satisfied Customers: 485
Experience: all ford training done asset grad.
fordman312009 and other Ford Specialists are ready to help you
Customer: replied 5 years ago.
OK. Thank you for the info. What I am looking for; is what do I need to do so that I can get to the compressor so that I can accomplish what you just sent me. I can't physically put a wrench on the 8mm bolt. What all do I have to remove to get it done.
Expert:  fordman312009 replied 5 years ago.
to be honest i always did it on the rack standing under it with the wheel off and some plastic shields and its still really tight i use a 8mm wrench the belt might hold the clutch from turning its a tuff job but it can be done

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