Compressor Clutch: Service and Repair

Compressor Clutch

REMOVAL






- When removing center bolt, hold clutch disc with clutch disc wrench.






- Remove the drive plate using the drive plate puller.
Insert the holder's three pins into the holes in the drive plate, and rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the drive plate.
When tightening the center bolt, insert a round bar (screwdriver, etc.) between two of the pins (as shown in the left-hand figure) to prevent drive plate rotation. After removing the drive plate, remove the shims from either the drive shaft or the drive plate.






- Remove the snap ring using external snap ring pliers.






- Pulley removal
Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller.
For pressed pulleys
To prevent deformation of the pulley groove, the puller claws should be hooked into (not under) the pulley groove. For machine latched pulleys
Align the pulley puller groove with the pulley groove, and then remove the pulley assembly.
- Remove the field coil harness clip using a screwdriver.






- Remove the three field coil fixing screws and remove the field coil.

INSPECTION






Clutch disc
If the contact surface shows signs of damage due to excessive heat, the clutch disc and pulley should be replaced.

Pulley
Check the appearance of the pulley assembly. If the contact surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and clutch disc should be replaced. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.






Coil
Check coil for loose connection or cracked insulation.

INSTALLATION
- Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's front head.
- Install the field coil harness clip using a screwdriver.






- Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.






- Install the drive plate on the drive shaft, together with the original shim(s). Press the drive plate down by hand.






- Using the holder to prevent drive plate rotation, tighten the bolt to 12 to 15 N.m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.
After tightening the bolt, check that the pulley rotates smoothly.






- Check clearance around the entire periphery of clutch disc.

Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in)

If the specified clearance is not obtained, replace adjusting spacer and readjust.

BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget break-in operation, accomplished by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.