Clutch Removal & Installation & Compressor Shaft Seal Replacement
FIGURE 1:
Clutch Removal
1. Prevent the clutch from turning using tool J-29635 and remove the compressor shaft nut (Fig. 1).
FIGURE 2:
2. Remove the clutch plate with puller J-29636 (Fig. 2). Make sure the puller is parallel to the plate.
FIGURE 3:
3. Remove key 1 and snap rings 2 and 3 (Fig. 3).
FIGURE 4:
4. Install the clutch pulley remover tool J-29637 (Fig. 4). Insert tool in the snap ring groove and place the protector on the compressor shaft.
FIGURE 5:
5. Remove the clutch pulley with a standard multi purpose puller A and appropriate size thumb screws B (Fig. 5).
FIGURE 6:
6. Remove snap ring C and remove the clutch D (Fig. 6).
Clutch Installation
1. Install the clutch D and snap ring C (Fig. 6).
FIGURE 3:
2. Align and install the pulley on the shaft.
3. Install snap ring 2 and 3 (Fig. 3).
NOTE: The snap rings have a flat edge and a beveled edge on the circumference. Position the snap rings so that the flat edge is toward the compressor and the beveled edge is outward.
4. Install compressor shaft key 1 (Fig. 3).
5. Install the clutch plate on the compressor shaft.
FIGURE 7:
6. Align the clutch plate keyway with the compressor shaft key and seat the plate with tool J-29641. Tap the plate onto the shaft until it bottoms on the shims.
7. Install and tighten the old retaining nut to 34-41 N-m (25-30 ft.lbs.) torque.
8. Check the clearance between the pulley and the clutch: this should be between 0.4 mm (0.016 in.) and 0.8 mm (0.031 in.).
a. If clearance is correct, remove the old nut and install a new nut. Tighten the new nut to 34-41 N-m (25-30 ft.lbs.) torque.
b. If clearance is incorrect, remove the nut, clutch plate and shims and make up the correct thickness shim pack.
^ If clearance is excessive, remove shims.
^ If clearance is insufficient, add shims.
9. Install the clutch plate and check clearance again. Tighten the new nut to 34-41 N-m (25-30 ft. lbs.) if clearance is correct.
2. COMPRESSOR SHAFT SEAL REPLACEMENT
Removal
1. Remove the compressor clutch as outlined in Compressor Clutch Service.
2. Remove the belt ring with snap ring pliers. Insert the pliers into the two holes in the metal ring retainer and lift out the ring.
FIGURE 8:
3. Remove the clutch shims (Fig. 8). Use O-ring hook J-9553-01 and a small screwdriver to prevent the shims from binding on the shaft during removal.
4. Remove the shaft seal seat snap ring (Fig. 8).
FIGURE 9:
5. Remove the shaft seal seat using tool J-9393-2 (Fig. 9).
CAUTION: When removing shaft seal O-Ring, do not scratch the O-Ring groove with the O-Ring hook.
FIGURE 10:
6. Use O-ring hook J-9553-01 to remove the shaft seal O-ring (Fig. 10).
FIGURE 11:
7. Remove the seal with tool J-29639 (Fig. 11). Insert the tool into the seal bore and press down against the seal spring. Twist the tool until it engages in the seal slots and lift the seal out.
FIGURE 12:
Installation
1. Clean the seal bore thoroughly with a lint-free cloth and clean refrigerant oil. Dry the bore with compressed air.
2. Install seal sleeve protector J-29640 over the compressor shaft (Fig. 12).
CAUTION: Do not touch the new seal lapping surfaces.
3. Dip the mating surfaces of the seal lapping surfaces in clean refrigerant oil.
4. Engage the slots of tool J-29639 in seal slots and install the seal firmly into place in the seal bore. Twist the tool in the opposite direction to disengage it from the seal.
CAUTION: When installing the shaft seal O-Ring, do not scratch the O-Ring groove with the O-ring hook.
5. Coat the O-ring with clean refrigerant oil and carefully place it in the seal groove with the O-ring hook.
6. Coat the seal retainer with clean refrigerant oil and install it with tool J-9393-2. Press the retainer lightly against the seal.
7. Install the snap ring with the beveled edge away from the compressor.
NOTE: It may be necessary to tap the snap ring lightly to seal it.
8. Install clutch spacer shims. Tap new felt ring into place and install compressor shaft key.
9. Install the clutch plate on the shaft and align the plate keyway with the compressor shaft key.
FIGURE 7:
10. Install the clutch plate with tool J-29641 (Fig. 7). Tap the plate onto the shaft until it bottoms on the clutch shims.
11. Install and tighten the compressor shaft nut to 31-41 N-m (25-30 ft.lbs.) torque.
12. Check and adjust pulley-to-clutch clearance as outlined in step 8 of the compressor clutch installation procedure.