Clutch

Compressor Clutch

Removal

NOTE: All the clutch service operations must be performed on a bench, and the following procedures strictly adhered to. The clutch includes a counter-weight on the front plate to improve dynamic balance.





1. Install service tool JD146 to the clutch front plate.





2. Fit the center bolt assembly, and position the holding shaft into the center bolt assembly locating hole.
3. Align the puller center bolt to the compressor shaft. Finger tighten the three puller bolts into the threaded holes.





4. Turn the center bolt clockwise until the front plate is loosened. Remove the plate and the shaft key.





5. Remove the internal bearing circlip by using pinch type circlip pliers only.





6. Remove the front housing circlip by using spread type circlip pliers.
7. Insert the lip of the puller jaws into the circlip groove.





8. Place the rotor shaft protector over the exposed shaft.





9. Align the thumb bolts to the puller jaws.





10. Turn the puller center bolt until the rotor puller is free.





11. Loosen the field coil lead from its clip on top of the compressor.





12. Using spread type of circlip pliers, remove the circlip and field coil.

Installation

NOTE:
- Install in the reverse order of removal utilizing the following additional procedures.
- The coil flange protrusion must match the hole in front of housing to prevent coil movement.

1. Position the field coil lead correctly.
2. Support the compressor on the four mounting ears at the rear of the compressor. If using a vice, clamp on the mounting ears NOT ON THE COMPRESSOR BODY.
3. Align the rotor assembly squarely on the front housing hub.





4. Using the rotor installer set, place the ring part of the set into the bearing cavity. Make certain the outer edge rests firmly on the rotor bearing outer race. Place the tool set driver into the ring.





5. With a hammer, tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub, Listen for a distinct change of sound during the tapping process.
6. Install the internal bearing circlip using pinch type of circlip pliers.
7. Refit the external front housing circlip using spread type of circlip pliers.
8. Check that the original clutch shims are in place on the compressor shaft and replace the compressor shaft key.
9. Align the front plate to compressor shaft key.
10. Using a shaft protector, tap the front plate until it bottoms on the clutch shims. Note distinct change of sound.
11. Refit the shaft nut and torque to 23-30 ft lb (3.4-4.2 kgf.m).





12. Check the air gap with a 0.016 to 0.031 inch feeler gauge.
13. If the gap is not consistant around the circumference, lightly tap down at the maximum gap and gently pry up at the minimum gap.

NOTE: The air gap is determined by the spacer shims. When fitting a new clutch assembly, try the original shims first. Add or subtract shims if the air gap does not meet the specifications.