Replacing the clutch on your Ford air-conditioning system is an easy way to save money. In many cases, the compressor functions perfectly, and the clutch simply has worn out. During the replacement of the clutch, replace the front seal as a precaution to prevent leaks. The tools for removing the clutch and installing the new one are available at your local auto parts store for sale, and in some cases for loan.
Recover the refrigerant in the system. A technician certified in refrigerant recovery and recycling does this. In addition, the equipment is very expensive. The most cost effective way to do this is to have a local auto repair shop recover the refrigerant. Most local auto repair shops can handle this for you.
Remove the serpentine drive belt by compressing the spring-loaded tensioner with a 3/8-inch drive socket wrench. It is not necessary to remove the belt from the vehicle. Remove the belt from the compressor clutch and position it out of the way.
Remove the clutch from the compressor by removing the retaining bolt in the center of the clutch assembly, and pulling the hub off with the clutch removal tool. Then remove the snap ring that retains the clutch pulley, and slide the clutch pulley off the compressor.
Pry the old compressor front seal out of the compressor, and install the new seal. Use a large socket from the set and a hammer to drive the new seal into place. Slide the compressor clutch onto the compressor, and install the snap ring. Then use the clutch installation tool to install the compressor clutch hub. Install the clutch-retaining bolt and tighten it securely.
Reinstall the belt by compressing the tensioner, and slipping the belt back onto the pulleys.
Evacuate and recharge the system. Attach the A/C gauge set to the vehicle's service ports, and attach the vacuum pump to the gauge set. Allow the vacuum pump to run for one hour to remove all the moisture from the system. Disconnect the vacuum pump, from the gauge set, and install the can tap that comes with the gauge set. Add refrigerant to the system until full. The system capacity is on a yellow tag on or near the accumulator. If the tag is missing, refer to the service manual for your specific Ford vehicle.
