How to replace air condition clutch/pulley on ford 6.0 diesel

The question is: How remove clutch in order to remove fan mounted on its engine-side face.

• Generally, the clutch drive half shaft must be uncoupled from coolant pump (impeller drive) half shaft using special wrench kit available as loaner from AutoZone (free with $79 approx deposit).
• Best done after shroud & radiator remove after coolant drained.

1. Uncouple coolant pump and fan clutch drive shaft(s) as follows:
   
   1. span across combo-pulley-sheaves-unit mounting bolt heads with large tool kit wrench, and
   2. span inline clutch coupling nut with small tool kit wrench. Then,
   3. turn small wrench (and coupling nut) CW while resisting with large wrench (CCW) to turn coupling nut until disengaged from coolant pump drive shaft.
2. Remove fan/clutch assembly.
3. Note direction of mounted fan hub and fan blades orientation to ensure proper re-assembly.
4. On rear of clutch assy, remove 4 bolts to disengage and remove fan.
5. Assemble new fan to clutch (or, preferably, new clutch and new fan) using new bolts and washers provided with fan.
6. Couple fan-clutch assy to coolant pump drive shaft as per opposite of uncoupling step 1, above. (Turn inline nut CCW to tighten...30 ft-lb.
7. Check that fan can be hand turned...CW.)
8. Rest shroud over and onto fan.
9. Replace radiator; remount shroud; reclamp hoses, and refill and air purge cooling system.

Clutch and Clutch Field Coil Printable View (235 KB)
Special Tool(s) 2-Jaw Puller
205-D026 (D80L-1002-L) or equivalent Installer, A/C Compressor Coil
412-065 (T89P-19623-EH) Holding Fixture, Compressor Clutch (3.8L vehicles)
412-098 (T94P-19703-AH) Holding Fixture, Compressor Clutch (4.6L vehicles)
412-103 (T95L-19703-AH) Remover, Differential Bearing
205-116 (T77F-4220-B1) Installer, A/C Compressor Field Coil
412-078 (T91L-19623-CH) Remover, A/C Compressor Field Coil
412-067 (T89P-19623-FH) Removal

1. Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor - 3.8L or Air Conditioning (A/C) Compressor - 4.6L in this section.

1. Remove the bolt.
   1. Hold the A/C disc and hub assembly (19D786) with the special tool.
   1. Remove the bolt.

1. Remove the A/C disc and hub assembly and the A/C clutch hub spacer (19D648).
   1. Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft.
   1. Lift the A/C disc and hub assembly and the A/C clutch hub spacer from the compressor shaft.

1. Remove the pulley snap ring.

1. Remove the A/C clutch pulley (2E884).

1. CAUTION: Do not use air tools. The A/C clutch field coil (19D798) can be easily damaged.
   Remove the A/C clutch field coil.
   1. Note the location of the A/C clutch field coil electrical connector.
   1. Install the special tool on the nose opening of the A/C compressor.
   1. Install the special tool.
   1. Remove the A/C clutch field coil.

Installation

1. NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.
   Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.
   • Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
   • Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth.
   • Inspect for roughness in the A/C compressor pulley bearing.

1. Clean the A/C disc and field coil and pulley mounting surfaces.

1. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
   Install the A/C clutch field coil.
   1. Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned.
   1. Using the special tools, install the A/C field coil.

1. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation.
   Install the A/C clutch pulley.

1. Install the pulley snap ring with the bevel side out.

1. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.

1. Install the A/C clutch.

1. Using the special tool, install the A/C disc and hub assembly retaining bolt.

1. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.

1. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 3.8L or Air Conditioning (A/C) Compressor - 4.6L in this section.

hope this helps

The pulley has no adjustment, if it is loose you have a bearing problem. If it only makes noise with the a/c on, I would suspect a clutch or compressor problem. Hope this helps, TJ

sounds like your fan clutch may be failing, remove the drive belt and manually spin all the pulleys by have listen for noise and feel for looseness in the bearings

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1 - a tank of the hydraulic booster of a steering; 2 - a plug mouth oil-jellied; 3 - a tank of a working liquid of a braking system and clutch; 4 - the assembly block of safety locks and the relay; 5 - an air filter; 6 - a windshield washer reservoir; 7 - the accumulator battery; 8 - the identification tablet; 9 - a measuring instrument of level of oil; 10 - an expansion chamber of system of cooling.

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1 - a tank of the hydraulic booster of a steering; 2 - a plug mouth oil-jellied; 3 - a tank of a working liquid of a braking system and clutch; 4 - the assembly block of safety locks and the relay; 5 - an air filter; 6 - a windshield washer reservoir; 7 - the accumulator battery; 8 - the identification tablet; 9 - a measuring instrument of level of oil; 10 - an expansion chamber of system of cooling.

It sounds like your air conditioning compressor or air conditioning clutches have gone bad the solution is to have rebuilt (or buy a rebuilt)air conditioning compressor. Do not attempt to work on thr compressor yourself unless you are certified in air conditioning, gas in system can kill you if you breeth it in.

If it is just the pulley,and not the compressor,then yes,the bearing for this is replacable for about 20 dollars or less,but if the compressor is locked up,you will have to replace the whole ac compressor,and it`s components.

You have to get get another compressor.

sounds like the air gap between pulley and a/c clutch is too much now due to wear. when it quits open hood and take a piece of wood or something and push on a/c clutch if it engages and starts back working this is problem. be careful when doing this

you can adjust air gap by removing nut and sliding off clutch there will be a couple washers in there take one out . be sure it will still free wheel when a/c is not on.

Probably a throw-out bearing, also called a clutch release bearing. It will eventually have to be replaced, and sooner better than later. If it freezes up completely, you can do some damage to the clutch assembly or release arm.