in-vehicle AC clutch replacement - what NOT to do - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace

Go Back   Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum > Ford Focus Tech Discussions > General Technical Chat

General Technical Chat This section is for technical discussions relating to general maintenance, electrical issues, engine trouble, and recalls.

Search This Forum | Image Search | Advanced Search    

LinkBack Thread Tools Display Modes
Old 11-08-2014, 12:01 PM   #1
Focus Addict
Join Date: Feb 2006
Fan#: 32386
Location: Chicago, IL
What I Drive: 2002 charcoal XZ3

Posts: 747
Points 1,540, Level 22
Points: 1,540, Level: 22 Points: 1,540, Level: 22 Points: 1,540, Level: 22
Level Up 40% Completed
Level up: 40% Level up: 40% Level up: 40%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 5 my_beautious_ZX3 Good Standing Member
Buy-Sell-Trade Rating: (0)
in-vehicle AC clutch replacement - what NOT to do

Just thought I'd share my experiences trying to replace the AC clutch pulley without removing the compressor. It's do-able, but......

I have slight bearing chatter on my AC clutch pulley, and decided to take advantage of the last warm day of 2014 to do some preventative maintenance on it. Since my compressor sees very little use (northern climate), I was willing to gamble that a pulley replacement would buy me another year or so until I sell this POS, rather than spend hundreds $$ on a new compressor, accumulator, evacuate/recharge, etc.

I purchased an aftermarket clutch assembly - nice because it comes with all of the necessary pieces. There's pretty much just one product available (Part #47869 for Zetec FS10 compressor, ~$80), sold under about four different brand names; all are identical and made by the same mfg:

So far, so good.

To access the AC compressor & serpentine tensioner, you might need to lower the engine. I provided a step-by-step procedure for that in an old thread . At a minimum, you will need to remove the belt guard.

The face of the pulley (clutch plate) is easily removed via the center bolt, which is only torqued to about 12 ft-lbs:

Keep an eye out for one or more small spacers (washers) that sit on its splined center. You'll need those if you reinstall the old parts.

After removing the serpentine belt, remove the pulley snapring, noting its orientation (large leg at 7 o'clock position, small leg at 5 o'clock):

The pulley is not pressed on. Grasp it with both hands and pull firmly to remove.

Now, the only thing remaining on the AC compressor is the field coil, which is pressed on:

At this point, you may reach the same conclusion that I did: there is no way to squeeze jaw-pullers in that cramped area, so I'll just do what folks in other car forums did - cut my losses and leave the old coil on there, and install the new pulley & pressure plate.


The aftermarket pulley will not fit over the OEM field coil. Prior to purchasing this kit, I called the manufacturer, who insisted that it would fit fine.. Thanks, bud.

At this point, I could have ordered a new pulley & pressure plate from a Ford dealer (~$150) or just a new pulley bearing (~$60). But, seeing that winter has come early to Chicago and I'm in an unheated garage, I decided to reinstall my old parts and return the new kit. If not forced to do so again in the meantime, I'll revisit this issue next spring.

Hindsight is 20/20
The next day, I decided to check Google with slightly different search terms, to see if anyone else ran into similar problems. I found a shop manual which stated:
Especially in the case of Ford FS6 and FX15/FS10 type clutches, complete replacement of the clutch and coil assembly is required. Original or replacement Ford OE clutch components cannot be mixed with aftermarket type clutch components (such as a Ford OE coil and an aftermarket pulley and hub).

"I'm jealous of girls because they get to wear dresses." (Todd Flanders)
my_beautious_ZX3 is offline  
    Reply With Quote Quick reply to this message
Sponsored Links
Old 11-08-2014, 08:30 PM   #2
Focus Fanatic
Join Date: Mar 2012
Fan#: 96610
Location: Fort Worth, TX
What I Drive: 00 wagon, 02 sedan both zetec atx

Posts: 15,100
Points 9,314, Level 64
Points: 9,314, Level: 64 Points: 9,314, Level: 64 Points: 9,314, Level: 64
Level Up 88% Completed
Level up: 88% Level up: 88% Level up: 88%
Forum Activity 100%
Activity: 100% Activity: 100% Activity: 100%
FF Reputation: 62 amc49 Excellent Standing Member
Buy-Sell-Trade Rating: (0)
Depends on who makes the clutch, I've switched coils and pulleys and worked fine. Some copycats follow design blueprints closely and some don't. Got a mismatch running on one of my cars now and works fine. Front plate, pulley and coil are all different from each other. I take a fine flat file and dress the hitting flats down some to let more material rub at engagement, it allows for a close gap to pull in easier too.

Next time just pull the four compressor mounting bolts and let compressor drop to work on it, no need to drop engine at all.
Fix the driver first, then fixing the car becomes so much easier..........
amc49 is offline  
    Reply With Quote Quick reply to this message

Bookmarks & Social Networks

Quick Reply

Register Now

In order to be able to post messages on the Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
What I Drive
Year, color, and model of your car. Example: 2003 Focus Centennial Edition Sedan
Your real name.
Please select your insurance company (Optional)


Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

All times are GMT -5. The time now is 09:00 PM.

Copyright 2002-2015 All Rights Reserved : : Advertise Information

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Mazda CX-3, Audi S3, Mazda MX-5 Miata and Acura TLX. You can find all Ford Focus, Focus ST and Focus RS related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area. If you own other makes have a look at Challenger Hellcat Forum, Charger Hellcat Forum, Cadillac ATS-V Forum, Cadillac CTS-V Forum, Lexus RC-F Forum, Lexus GS-F Forum, Mercedes GLA Forum, Mercedes GLE Forum and Volvo XC90 Forum.


Search Engine Optimization by vBSEO 3.6.1