Questions and Answers

Intrepid A/C

Q. I own a 1996 Dodge Intrepid 3.5 liter. Last summer the Air Conditioning unit stopped spinning. Luckily it runs on its own belt. I was able to cut it off and keep driving. How do I determine if the A/C condenser is broken or if it is the pulley and bearings. A lot of thick hot black stuff was coming out of the back part of the pulley area. How do I replace these things or do I need to seek a professional. I am usually able to fix almost anything.

Thank you, Jerry

A. I don't know Jerry, I find it hard to get into A/C's right now. It's 4 degrees outside and I find that's plenty of A/C for me.

A few years ago it was okay for anyone to do their own A/C work. Now you need to be licensed to do A/C work and show you have the proper equipment to do the work without doing damage to the environment.

If it is a damaged clutch assembly, you can replace it without having to discharge the refrigerant. From what you describe, it sounds like the clutch coil had a melt down. If that's the case, chances are the compressor itself is still okay. Replacing the clutch, clutch coil and pully should fix you up. The parts will run you about $100.00. There's no big deal to changing it. Here's what you need to do:

1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal.
2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s).
3. Remove pulley retaining snap ring with snap ring pliers and slide pulley assembly off of compressor.
4. Remove coil wire bracket/ground clip screw and wire harness.
5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing.

To install the new one:

1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw.
2. Install field coil retaining snap ring with snap ring pliers. Press snap ring to make sure it is properly seated in the groove.

   NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Make sure the snap rings are fully seated also.

3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface.
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove.

   NOTE: The bevel side of the snap ring must be facing outward.

5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft.
7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure:
   • Attach a dial indicator to front plate so that movement of the plate can be measured.
   • With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement.
   • The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained.
8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.).

   NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.

CLUTCH BREAK-IN:
After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability.

NOTE: Excessive clutch gap will result in clutch slippage or non-engagement.

Information provided courtesy of ALLDATA