Question about 1999 Plymouth Voyager

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1999 Plymouth Voyager a/c works but freezes up and burns belt. Any help? Thanks

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  • Donna Jun 29, 2009

    Is this part difficult to replace?

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  • Plymouth Master
  • 2,984 Answers

The compressor clutch is bad on the A/C compressor.

Posted on Jun 29, 2009

  • Greg Bernett
    Greg Bernett Jun 29, 2009

    I'll print the task for it:



    NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged.


    1. Disconnect and isolate the negative battery cable.
    2. Remove the compressor.
    3. Remove the compressor shaft bolt. A strap wrench or oil filter wrench may be used to prevent the clutch from turning.
      CAUTION
      Do not attempt to pry the clutch plate from the compressor shaft as this may damage the clutch plate.

      NOTE: Make sure to save the clutch shims.

    4. Tap the clutch plate lightly with a plastic mallet to release it from the compressor and remove the clutch plate. Remove and save the shims(s) if equipped.
    5. Remove the snap ring that secures the pulley and bearing assembly to the compressor and then remove the pulley and bearing assembly.
    6. Remove the clutch wiring from the bracket.
    7. Using snap ring pliers remove the snap ring that secures the clutch coil to the front of the A/C compressor and remove the coil.

    To Install:


    1. Align the dowel on the back of the clutch coil with the hole in the front of the compressor and place the coil on the compressor.
      CAUTION
      Make sure the snap ring is fully seated in the groove or it will vibrate out, resulting in clutch failure and severe damage to the compressor.

    2. Install a new snap ring that secures the clutch coil to the compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or left of the coil dowel pin location on the A/C compressor.
      CAUTION
      Be careful not to damage the clutch coil wire during assembly.

      CAUTION
      Make sure not to damage the clutch friction surfaces in any way during installation. Premature clutch failure will result.

    3. Install the pulley and bearing assembly on the compressor. Tap the pulley gently if necessary with a block of wood placed on the surface.
      CAUTION
      Make sure the snap ring is fully seated in the groove or it will vibrate out, resulting in clutch failure and severe damage to the compressor.

    4. Install the snap ring that secures the pulley and bearing assembly to the compressor. The bevel side of the snap ring must face outward. Be certain that the snap ring is fully seated in the groove.
    5. If the original clutch plate and pulley and bearing assembly are to be reused, reinstall the original shim(s) onto the compressor shaft. If a new clutch plate, pulley and bearing assembly is being used, install a stack of shims 0.040 in. (1.0 mm) thick onto the compressor shaft.
    6. Install the clutch plate and compressor shaft bolt. Tighten the bolt to 155 in. lb. (17.5 Nm).
      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 correct. Spin the pulley before performing a final check of the air gap.

      NOTE: You will need a 90° wire gap gauge to measure the clutch air gap on models with the clutch plate recessed into the pulley.

    7. Measure the air gap between the clutch plate and the pulley. The air gap should be between 0.020 - 0.035 in. (0.5 - 0.9 mm). Add or subtract shims as needed until the correct air gap is obtained.
    8. Install the compressor.
    9. Connect the electrical connector to the compressor clutch.
    10. Connect the negative battery cable.

    NOTE: Cycle the A/C clutch on and off at about 5 second intervals to break in the clutch friction surface. Do this at least 20 times.

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