Question about 1995 Plymouth Voyager

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I need to replace the a/c clutch, hopefully not the compressor, from my 1995 3.3L Voyager. What are the steps to do this?

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  • Expert
  • 123 Answers

I`ve just found this in the manual:

The refrigerant system can remain fully charged
during compressor clutch, pulley, or coil replacement.
Although the compressor assembly must be removed
from its mounting, the compressor clutch can be service
with the compressor in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
(3) Remove the serpentine drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
2.4L - REMOVAL) or (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - 3.3/3.8L - REMOVAL).
(4) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil pigtail
wire connector on the top of the compressor.
(5) On models with the 3.3L and 3.8L engines, disengage
the retainer on the engine wire harness compressor
clutch coil take out from the bracket on the
top of the compressor.
(6) On models with the 2.4L engine, remove all of
the compressor mounting screws except the upper
left (rear of the compressor) screw, which should only
be loosened. Allow the front (pulley end) of the compressor
to tilt downward far enough to access the
clutch for removal, then tighten the loosened upper
left compressor mounting screw.
(7) On models with the 3.3L and 3.8L engines,
remove the three screws and one nut that secure the
compressor to the engine. Disengage the mounting
ear at the front of the compressor from the stud on
the engine, allow the front (pulley end) of the compressor
to tilt downward far enough to access the
clutch for removal, then reinstall and tighten the
upper left compressor mounting screw.
(8) Remove the compressor shaft bolt (Fig. 13). If
necessary, a band-type oil filter wrench or a strap
wrench can be placed around the clutch plate to aid
in bolt removal.
(9) Tap the clutch plate lightly with a plastic hammer
and remove the clutch plate and shim(s) from
the compressor shaft (Fig. 14). Be certain not to
lose the shim or shims.
CAUTION: Do not pry between the clutch plate unit
and the pulley to remove the clutch plate from the
compressor shaft as this may damage the clutch
plate.
(10) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the pulley to the front cover of the compressor,
then slide the pulley off of the compressor (Fig.
15).
(11) Remove the screw that secures the clutch coil
pigtail wire connector bracket and ground clip to the
top of the compressor housing.
(12) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the clutch coil to the front cover of the compressor
housing, then slide the clutch coil off of the
compressor (Fig. 16). I hope this is of use to you. Ian

Posted on Jul 23, 2009

  • Ian Percy Jul 23, 2009


    INSPECTION - COMPRESSOR CLUTCH/COIL

    Compressor clutch components should always be

    inspected closely before they are reinstalled. The

    clutch plate and clutch pulley are mated at the factory

    using a burnishing operation. No attempt should

    be made to separately replace the compressor clutch

    pulley or clutch plate. The clutch coil may be serviced

    separately.

    (1) Examine the friction surfaces of the clutch pulley

    and the clutch plate for wear. The clutch pulley

    and clutch plate should be replaced if there is excessive

    wear or scoring.

    (2) Examine the friction surfaces of the clutch pulley

    and the clutch plate for oil contamination. If the

    friction surfaces are oily, the clutch pulley and clutch

    plate should be replaced. Also inspect the shaft and

    nose area of the compressor for oil. Remove the felt

    packing from around the compressor shaft in the

    compressor front cover. If the felt is saturated with

    oil, the compressor front shaft seal is leaking and the

    compressor will also have to be replaced.

    (3) Check the clutch pulley bearing for roughness

    or excessive leakage of grease. Replace the clutch

    pulley and clutch plate if the bearing is faulty.

    INSTALLATION

    The refrigerant system can remain fully charged

    during compressor clutch, pulley, or coil replacement.

    Although the compressor assembly must be removed

    from its mounting, the compressor clutch can be service

    with the compressor in the vehicle.

    (1) Align the dowel pin on the back of the clutch

    coil with the hole in the compressor front cover, and

    position the clutch coil onto the compressor. Be certain

    that the clutch coil pigtail wires are properly oriented

    and routed so that they are not pinched

    between the compressor front cover and the clutch

    coil.

    NOTE: A new snap ring must be used to secure the

    clutch coil to the compressor. The bevel side of the

    snap ring must face outward.

    (2) Using snap ring pliers (Special Tool C-4574 or

    equivalent), install the external snap ring that

    secures the clutch coil to the front cover of the compressor

    (Fig. 16). The bevel side of the snap ring

    must face outward and both snap ring eyelets must

    be oriented to the right or the left of the clutch coil

    dowel pin location on the compressor. Be certain that

    the snap ring is fully and 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 compressor front

    cover.

    (3) Install and tighten the screw that secures the

    clutch coil pigtail wire connector bracket and ground

    clip to the top of the compressor housing.

    (4) Install the pulley onto the front cover of the

    compressor. If necessary, tap the pulley gently with a

    block of wood placed on the pulley friction surface

    (Fig. 17).

    CAUTION: Do not mar the friction surfaces of the

    pulley.

    NOTE: A new snap ring must be used to secure the

    clutch pulley to the compressor. The bevel side of

    the snap ring must face outward.

    (5) Using snap ring pliers (Special Tool C-4574 or

    equivalent), install the external snap ring (bevel side

    facing outward) that secures the clutch pulley to the

    front cover of the compressor (Fig. 15). Be certain

    that the snap ring is fully and properly seated in the

    groove.

    (6) If the original clutch plate and clutch pulley

    are to be reused, reinstall the original shim(s) on the

    compressor shaft against the shoulder (Fig. 14). If a

    new clutch plate and/or clutch pulley are being used,

    install a trial stack of shims 1.0 mm (0.040 in.) thick

    on the compressor shaft against the shoulder.

    (7) Install the clutch plate onto the compressor

    shaft.

    (8) Install and tighten the compressor shaft nut

    (Fig. 13). If necessary, a band-type oil filter wrench

    or a strap wrench can be placed around the clutch

    plate to aid in bolt tightening. Tighten the bolt to

    17.5 N·m (155 in. lbs.).

    (9) If a new clutch plate and/or clutch pulley are

    being installed, the air gap between the clutch plate

    and clutch pulley must be checked. (Refer to 24 -

    HEATING & AIR CONDITIONING/CONTROLS -

    FRONT/COMPRESSOR CLUTCH - STANDARD

    PROCEDURE - COMPRESSOR CLUTCH AIR GAP).

    (10) On models with the 2.4L engine only, loosely

    install the four screws that secure the compressor to

    the mounting bracket on the engine. Tighten the

    screws to 28 N·m (21 ft. lbs.).

    (11) On models with the 3.3L and 3.8L engines

    only, loosely install the three screws and one nut that

    secure the compressor to the engine. Tighten each of

    the fasteners using the following sequence to 54 N·m

    (40 ft. lbs.).

    † The upper screw at the rear of the compressor.

    † The lower screw at the rear of the compressor.

    † The lower screw at the front of the compressor.

    † The upper nut at the front of the compressor.

    (12) On models with the 3.3L and 3.8L engines

    only, engage the retainer on the engine wire harness

    compressor clutch coil take out with the bracket on

    the top of the compressor.

    (13) Reconnect the engine wire harness connector

    for the compressor clutch coil to the coil pigtail wire

    connector on the top of the compressor.

    (14) Reinstall the serpentine accessory drive belt

    onto the front of the engine. (Refer to 7 - COOLING/

    ACCESSORY DRIVE/DRIVE BELTS - 2.4L -

    INSTALLATION) or (Refer to 7 - COOLING/ACCESSORY

    DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTALLATION).

    (15) Lower the vehicle.

    (16) Reconnect the battery negative cable.

    (17) If a new clutch plate and/or clutch pulley are

    being installed, the new clutch components must be

    burnished. (Refer to 24 - HEATING & AIR CONDITIONING/

    CONTROLS - FRONT/COMPRESSOR

    CLUTCH - STANDARD PROCEDURE - COMPRESSOR

    CLUTCH BREAK-IN).

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  • Plymouth Master
  • 6,826 Answers

U need a speacial tool clutch tool removel tool

Posted on Jun 30, 2009

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