The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle.
Disconnect and isolate the battery negative cable.
Remove the serpentine drive belt. Refer to Cooling System for the procedures.
Remove the bolt that secures the compressor clutch to the compressor shaft Compressor Shaft Bolt A band-type oil filter wrench may be used to secure the clutch during bolt removal
Tap the clutch plate with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft Clutch Plate and Shim
CAUTION: Do not pry between the clutch plate assembly and the pulley to remove it from the compressor shaft. Prying may damage the clutch plate assembly.
Remove the external snap ring that secures the compressor clutch pulley to the nose of the compressor front housing with snap ring pliers (Special Tool C-4574) and slide the pulley assembly off of the compressor Pulley Snap Ring Remove/Install
Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing.
Remove the external snap ring that secures the compressor clutch coil to the nose of the compressor front housing with snap ring pliers and slide the coil assembly off of the compressor Clutch Coil Snap Ring Remove/Install
Examine the friction surfaces of the clutch pulley and the clutch plate for wear. The pulley and plate should be replaced if there is excessive wear or scoring.
If the friction surfaces are oily, inspect the shaft and nose area of the compressor for refrigerant oil. Remove the felt wick from around the shaft inside the nose of the compressor front housing. If the felt is saturated with refrigerant oil, the compressor shaft seal is leaking and the compressor must be replaced.
Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required.
Align the dowel pin on the back of the clutch field coil with the hole in the compressor front housing and press the field coil into place over the nose of the compressor.
Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw.
Install the clutch field coil and snap ring with snap ring pliers (Special Tool C-4574) The bevel side of the snap ring must be facing outward. Also, both eyelets of the snap ring must be to the right or left of the pin on the compressor. Press in on the snap ring to be certain that it is properly seated in the groove
CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.
Install the pulley assembly onto the compressor. If necessary, place a block of wood on the friction surface and tap gently with a hammer Pulley Assembly Install
CAUTION: Do not mar the pulley friction surface.
Install the pulley assembly retaining snap ring (bevel side outward) with snap ring pliers (Special Tool C-4574) Press in on the snap ring to be certain that it is properly seated in the groove
If the original clutch plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a stack of shim(s) equal to the old shim(s) on the shaft against the shoulder.
Install the clutch plate assembly onto the shaft.
With the clutch plate assembly tight against the shim(s), measure the air gap between the clutch plate and the pulley face with feeler gauges. The air gap should be between 0.35 to 0.65 millimeter (0.014 to 0.026 inch) If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
Install the compressor shaft bolt. Tighten the bolt to 13 N·m (115 in. lbs.)
NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley before performing a final check of the air gap.
Reverse the remaining removal procedures to complete the installation.
After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off) During this procedure, set the heater-A/C control in the Recirculation Mode, the A/C button in the on position, the blower motor switch in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.
96 GC Limited V8 245,000 miles Scrapped
04 GC Limited 4.0 264,000 miles
96 GC 4.0 175,000