1. Check the condition of the belt tensioner pulley.
2. If the belt was replaced when the AC was changed make sure you have the correct belt. Check the ford part number.
3. Ensure the AC compressor has been bolted into position correctly. Also ensure the pulley on the compressor is the correct spec.
4. Check for any abnormal free play in any of the idler pulleys.
If the idler and nearby pulleys are all in-line, not excessively worn and the axis is exactly at a right-angle to the belt run the belt should not pop off, therefore either the idler or other pulleys are worn tapered or sagging or it is possible the belt has become stretched on one edge.
You could try turning the belt around so it is traveling in the opposite direction and see if it makes any difference. Some idler pulleys will also turn round if required.
I hope this provides food for thought.
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