clutch DODGE RAM 1999 Service User Guide

Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove compressor. Drain, measure and
discard refrigerant oil from compressor. Remove clutch plate, clutch
pulley, shims, and clutch coil. See CLUTCH ASSEMBLY. See Fig. 4.
2) Using a flat-blade screwdriver, remove felt ring and felt
washer from front housing. Remove shaft key and shaft seal snap ring.
Insert Compressor Shaft Seal Remover/Installer (J-33942-B) into seal.
Turn seal remover/installer until contact with notches in seal is
made. Remove shaft seal.
Installation
1) Install Compressor Shaft Seal Protector (J-34614) onto
compressor shaft. Lubricate NEW shaft seal with refrigerant oil. DO
NOT touch sealing surfaces. Engage seal remover/installer into seal
notches and install seal onto compressor shaft. Remove seal protector
and remover/installer.
2) Install seal snap ring. Install felt washer and felt ring.
Install clutch plate, clutch pulley, shims, and clutch coil. See
CLUTCH ASSEMBLY. See Fig. 4. After repairs, add refrigerant oil to
compressor equal to amount drained. To complete installation, reverse
removal procedure. Perform leak test.
Fig. 4: Compressor Components (Nippondenso 10-Cylinder)
Courtesy of general motors corp.
NIPPONDENSO 10PA17/10PA17C 10-CYLINDER

CLUTCH ASSEMBLY
Removal (Except Grand Cherokee)
Remove compressor shaft bolt. Remove clutch plate and shims.
Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub
and shims. Remove snap ring, and remove rotor and pulley assembly.
Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Install dial indicator at front of clutch hub to measure
clutch hub air gap. Using battery voltage, energize clutch coil.
Proper air gap is 0.014-0.026" (0.35-0.65 mm). Add or remove shims to
obtain correct air gap. Install compressor shaft bolt. On Concord and
Intrepid, tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m).\
On all other models, tighten compressor shaft bolt to 10 ft. lbs. (14
N.m).
NOTE: On Grand Cherokee, compressor clutch can be serviced in
vehicle without discharging A/C system.
Removal (Grand Cherokee)
Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Remove compressor shaft bolt. Using a plastic
mallet, tap clutch plate to loosen from compressor shaft. Remove
clutch plate, shaft key and shims. See Fig. 5. Remove snap ring, and
remove pulley assembly. Remove snap ring, and disconnect clutch coil
lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Align snap ring eyelets to the left or right of
clutch coil pin. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Hold clutch plate tight against shims and measure air gap
between clutch plate and pulley face. Air gap should be 0.014-0.026"
(0.35-0.65 mm). Add or remove shims as necessary. Install compressor
shaft bolt. Tighten compressor shaft bolt to 115 INCH lbs. (13 N.m).
To complete installation, reverse removal procedure.
3) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
NOTE: Shaft seal replacement procedure is for 10PA17C compressor.
Shaft seal replacement procedure for 10PA17 compressor is not
available.
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain oil from
compressor, and measure amount drained. Remove clutch hub, shims,
rotor and pulley assembly, and clutch coil. See CLUTCH ASSEMBLY. See

Fig. 5.
2) Remove front housing. Remove felt holder and felt washer
from front housing. Remove shaft seal snap ring. Position front
housing (nose up) on cardboard, placed on a flat surface. Using brass
drift, press shaft seal from front housing.
Installation
1) Lubricate new shaft seal with refrigerant oil. DO NOT
touch sealing surfaces. Using a 21-mm socket, press seal into front
housing, and install snap ring. Ensure shaft seal "O" ring side is
facing the front housing (away from compressor). Install felt washer
into felt holder. Using a 14-mm deep socket, install felt washer and
felt holder.
2) Lubricate front housing "O" ring with refrigerant oil.
Install shaft seal protector on compressor shaft. Install new front
housing "O" ring on compressor assembly.
3) Install front housing on compressor assembly. Ensure dowel
pins are aligned. Use care when guiding shaft seal protector through
seal opening. Remove shaft seal protector.
4) Install through-bolts and new brass washers. Using an
INCH-lb. torque wrench, check compressor shaft rotating torque.
Rotating torque should be 45 INCH lbs. (5 N.m) or less. Install clutch\
coil and check clutch hub air gap. See CLUTCH ASSEMBLY.
5) Using refrigerant oil, add same amount of oil to
compressor as was drained from it. Install A/C compressor. Evacuate
and charge system. Perform leak test.
Fig. 5: Compressor Components (Nippondenso 10PA17C Shown; Nippondenso
10PA17 Is Similar)
Courtesy of chrysler corp.
SANDEN SCROLL

Ford Motor Co. (Taurus 3.4L SHO)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain and measure
oil from compressor.
2) Remove pulley assembly. Using Spanner Wrench (T81P-19623-
MH), remove shaft nut and lock washer. Using a steering wheel puller,
remove clutch plate, shaft key and shim. Remove snap ring and pulley
assembly, by hand. If necessary, use a 3-jaw puller to remove pulley
assembly. Remove clutch coil wire from retaining brace on compressor.
Remove snap ring and clutch coil. See Fig. 1.
Installation
1) Install clutch coil. Ensure hole on back of clutch coil is
aligned with pin on compressor head. Install snap ring with beveled
side facing outward. Install clutch coil wire into retaining brace.
2) Slip pulley assembly onto compressor shaft and install
snap ring with beveled side facing outward. Install shim and shaft
key. Align clutch plate with shaft key and install clutch plate. Use
Hub Driven Plate Replacer (T80L-19703-F), if necessary. Using spanner
wrench, install lock washer and shaft nut. Tighten shaft nut to 10-14
ft. lbs. (14-19 N.m).
3) Using a feeler gauge, measure air gap between clutch plate
and pulley assembly at 3 equally spaced locations. Rotate pulley 180
degrees and measure air gap at 3 locations again. Air gap should be 0.
016-0.027" (0.41-0.69 mm). If air gap is not within specification, add\
or remove shims to obtain correct air gap.
4) Add correct amount of refrigerant oil to compressor and
install compressor. See COMPRESSOR REFRIGERANT OIL CHECKING. Evacuate
and charge A/C system. Perform leak test.
SANDEN MSC90-C SCROLL
CLUTCH ASSEMBLY
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove compressor. Drain oil from
compressor, and measure amount drained.
2) Remove pulley assembly. Using Spanner (MB991367) and Pins\
(MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor\
assembly. Remove snap ring and clutch coil. See Fig. 6.
Installation
1) Install clutch coil. Ensure projection on back of clutch
coil is aligned with pin hole in compressor body. Install snap ring so
that tapered surface is facing outward.
2) Install rotor assembly and snap ring. Align match mark of
clutch plate with match mark of compressor shaft spline and install
clutch plate. Using spanner and pins, install shaft nut.
3) Using a feeler gauge, check air gap between clutch plate
and rotor assembly at more than one place. Air gap should be 0.016-0.
024" (0.40-0.60 mm). If air gap is not within specification, add or
remove shims as necessary. Install pulley assembly.
4) Add same amount of refrigerant oil to compressor as was
drained from it. Install A/C compressor. Evacuate and charge A/C
system. Perform leak test.

Fig. 6: Compressor Components (Sanden MSC90-C Scroll)
Courtesy of chrysler corp.
SANDEN SD-7H15 7-CYLINDER
NOTE: On Cherokee, Dakota, Durango, Ram Pickup and Wrangler,
compressor clutch can be serviced in vehicle, without
discharging A/C system.
CLUTCH ASSEMBLY
Removal (Cherokee, Dakota, Durango, Ram Pickup & Wrangler)
1) Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Disconnect clutch coil harness connector.
Without disconnecting refrigerant lines, remove A/C compressor from
mounting bracket. Support compressor in engine compartment.
2) Using spanner wrench, hold clutch plate and remove
compressor shaft nut. See Fig. 1. Using a steering wheel puller,
remove clutch plate, compressor shaft key and shims. Remove external
front housing snap ring.
3) Install jaws of Rotor Puller (C-6141-1) into pulley snap
ring groove. Install Shaft Protector (C-6141-2) over compressor shaft.\
Install puller flange plate on jaws. Install Puller Through-Bolts (C-
6461) through puller flange plate into jaws and hand tighten. Tighten
pulley center bolt clockwise and remove pulley from compressor.
4) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.

Installation (Cherokee & Wrangler)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub. Using Installer (C-
6871), press pulley and bearing assembly onto compressor housing hub.
Thread installer on compressor shaft and tighten nut until pulley
assembly is seated.
2) Install external front snap ring with beveled side facing
outward. Ensure snap ring is properly seated. Install compressor shaft
key and original shims. Using a plastic mallet and Driver (C-6463),
install clutch plate on compressor shaft. Tighten compressor shaft nut
to 10 ft. lbs. (14 N.m).
3) Using feeler gauge, measure air gap between clutch plate
and pulley assembly in several areas. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. If air gap is not consistent around clutch
plate, lightly pry up or tap down on clutch plate to make corrections.
To complete installation, reverse removal procedure.
Installation (Dakota, Durango & Ram Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install Handle (6464) and Driver (6143) into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing. Install external snap ring.
3) Install original shim(s) and compressor shaft key. Use a
hammer and Shaft Protector (6141-2) to install clutch plate on
compressor shaft. Ensure clutch plate bottoms out on clutch shims.
Replace compressor shaft nut and tighten compressor shaft nut to 10
ft. lbs. (14 N.m).
4) Measure air gap between clutch plate and pulley assembly
in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If
air gap is not within specification, adjust shim thickness as
necessary. If air gap is not consistent around clutch plate, lightly
pry up or tap down on clutch plate to make corrections. To complete
installation, reverse removal procedure. Ensure A/C system operates
properly.
5) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
Removal (Ford "F" Series Super Duty Pickup)
1) Disconnect and isolate negative battery cable. Discharge
A/C system, using approved refrigerant recovery/recycling equipment.
Disconnect clutch coil harness connector and remove compressor. Drain
oil from compressor, and measure amount drained.
2) Using Spanner Wrench (T70P-4067-A), hold clutch plate and\
remove compressor shaft nut. See Fig. 1. If necessary, use a steering
wheel puller to remove clutch plate and shim(s).
3) Using a flat-blade screwdriver, remove pulley assembly
bearing dust cover. Remove compressor shaft key and internal bearing
snap ring. Remove external front housing snap ring.
4) Install jaws of rotor puller into pulley assembly internal
bearing snap ring groove. Install shaft protector over compressor
shaft. Install puller flange plate on jaws. Install 2 puller bolts
through puller flange plate into jaws and hand tighten. Tighten pulley
center bolt clockwise and remove pulley assembly from compressor.

5) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.
Installation (Ford "F" Series Super Duty Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install pulley installer handle and driver into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing.
3) Install internal bearing and external front housing snap
rings. Install original shim(s) and compressor shaft key. Using a
hammer and shaft protector, install clutch plate on compressor shaft.
Ensure clutch plate bottoms out on clutch shims. Replace compressor
shaft nut and tighten compressor shaft nut to 25-30 ft. lbs. (34-41 N.
m).
4) Measure air gap between clutch plate and pulley assembly
in 3 locations spaced equally around pulley. Rotate clutch pulley 180
degrees and check air gap as specified. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. To complete installation, reverse removal
procedure. Evacuate, charge, and leak test A/C system.
SANDEN TRS-90 & TR-105 SCROLL
CLUTCH ASSEMBLY
Removal
1) Without discharging A/C system, remove compressor from
mount. Install two 6-mm bolts in holes of clutch plate. Use 6-mm bolts
and 2 box-end wrenches to hold clutch plate while removing nut from
end of compressor shaft.
2) Remove clutch plate and shims. Using a plastic hammer, tap
clutch plate to loosen from compressor (if necessary). DO NOT pry
between clutch plate and pulley to remove clutch plate.
3) Remove pulley assembly snap ring. Remove pulley assembly.
Disconnect clutch coil lead. Scribe marks on clutch coil and
compressor for installation reference. Remove snap ring and clutch
coil.
NOTE: Rotor/pulley assembly and clutch plate are a matched pair and
should be replaced together.
Installation
1) Install clutch coil on compressor so locating pin engages
locating indentation. Install snap ring with beveled side away from
compressor. Secure clutch coil lead to compressor front cover and
connect lead to thermal limiter switch.
2) Install pulley assembly. Install snap ring with beveled
side away from compressor. If reusing original clutch plate and
pulley, old shims can be used.
3) If new components are used, install several shims so shim
pack thickness is 0.10" (2.5 mm). Align machined match marks and
install clutch plate and hold it tightly against shims.
4) Measure air gap between clutch plate and pulley surface.
Air gap should be 0.013-0.025" (0.33-0.64 mm). Adjust shim thickness
as necessary. On TRS-90, tighten compressor shaft nut to 13 ft. lbs.
(18 N.m). On TR-105, tighten compressor shaft nut to 10 ft. lbs. (14
N.m).

5) Once compressor shaft nut is tightened, check air gap
between clutch plate and pulley surface in at least 4 places. Readjust
air gap if necessary. Install A/C compressor. Evacuate and charge
system. Perform leak test. Ensure A/C system is operating properly.
6) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
Shaft seal is not serviceable. If excessive oil is present on
pulley and plate friction surfaces or on compressor shaft nose area,
replace compressor.
ZEXEL ROTARY VANE
CLUTCH ASSEMBLY
NOTE: Discharging A/C system and removing refrigerant lines from
compressor is not necessary to service clutch assembly.
Removal
1) Loosen tensioner and remove drive belt from pulley.
Disconnect clutch electrical connector. Remove compressor mounting
bolts. With refrigerant lines connected lift compressor upward and
forward. Install one front mounting bolt through bottom rear
compressor mounting ear. Tighten bolt so compressor is supported by
mounting bracket.
2) Using Clutch Drive Plate Holder (SA9510AC), remove clutch\
drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve
(SA9506AC) into center of drive plate. Install remover bolt. While
holding clutch remover sleeve, tighten remover bolt and remove drive
plate and shims.
3) Remove pulley external snap ring. Position Puller Center
Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller\
to back of pulley. Tighten puller bolt against pulley center adapter
and remove pulley. Remove clutch coil screws. Disconnect clutch coil
wire. Remove clutch coil.
Installation
1) Install coil in original position. Ensure electrical
connector is aligned with indent in front of compressor head. Tighten
screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC\
-
3) and thrust bearing on installation bolt and insert through center
of pulley. Finger-tighten pulley installation bolt into compressor
shaft.
2) Finger-tighten nut on installation bolt to align pulley to
compressor. Hold end of bolt and tighten nut until pulley bottoms on
compressor. Loosen nut and remove installation bolt, thrust bearing
and drive plate installer. Install snap ring with tapered side out.
3) Install thrust bearing on installation bolt and insert
through clutch drive plate. Place original shims on installation bolt.
Thread bolt into compressor shaft. Hold end of bolt and tighten nut
until clutch drive plate bottoms out. Loosen nut and remove
installation bolt and thrust bearing. Install center bolt and tighten
to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
4) Using a feeler gauge, measure air gap between drive plate
and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap
is not as specified, add or remove shims as necessary. Install
compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs.


A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS

Fig. 5: A/C Compressor & Compressor Clutch Diagnosis (1 Of 2)
Courtesy of Chrysler Corp.