Help needed with Aircon

[ragandstick]

Can anyone help? My Mondeo 1999 T reg aircon compressor clutch is not pulling in and I have been told it can be fixed by shim removal. The trouble is I can find no info on how this is done and no diagrams or descriptions of how the clutch is assembled. The Haynes manual is of no help as it only describes removal of the whole compressor.

[finlo]

ragandstick said:

Can anyone help? My Mondeo 1999 T reg aircon compressor clutch is not pulling in and I have been told it can be fixed by shim removal. The trouble is I can find no info on how this is done and no diagrams or descriptions of how the clutch is assembled. The Haynes manual is of no help as it only describes removal of the whole compressor.

Is there any gas in it?

[neiljohnson]

Take the nut off of the centre of the clutch disc when you remove it you will find a small washer, throw it away, bolt clutch back on and away you go.

[ragandstick]

Thanks for the replies. I had the system checked and there is gas there. The guy who checked it established there was power to the clutch by using a test light with a needle probe to stick into the feed cable.( a device so simple and clever I've made one!) He then used a wooden lever to push the clutch centre in and it operated. He said it was a "lazy" clutch and a replacement compressor was needed. I went to the Ford agent in Chichester yesterday and he quote £501 to supply and fit an exchange unit. Needless to say I would like to try the removal of the washer suggested by Neil and would ask is it necessary to remove the comprssor to do this? There looks as though there may be enough room if the driver side wheel and wheel arch cover are removed. Thanks Dave Tedd

[neiljohnson]

Can be done in situ is real easy takes abount 10 mins on a ramp, prob a bit longer on the floor though.

[Nighthawk]

it may well have gas in it, but are the low pressure and high pressure switches ok?

Also, if there was 12v at the clutch windings, was there enough current?
It's possible to have a chaffed cable further back away from the compressor which will show 12v but has too much resistance to allow adequate current flow

[ragandstick]

I have been busy so have only just got around to trying Neil's suggestion. I took off the front wheel and the inner plastic cover and was able to get at the 8mm bolt with a small socket and remove the clutch plate. It was worn down about 1mm and sure enough there was a 1.14 mm shim on the inside face which I removed. Sure enough the clutch now pulls in OK. To think that 3 specialists said I needed a new compressor at about £400 to £500 is scandalous. My system is still not functioning as the clutch pulls in and drops out after 5 seconds and then repeats this every 20 seconds or so. I have tried regassing using a 12oz can on the LP side but only about half the can has gone in and the problem is still there. Does anyone have any ideas as I think I will need to have a full system regas? Thanks again for your valuable help.