I'm pretty sure that the AC compressor and/or clutch has just failed on my
'92 Astro Van (210,000 miles). Can anyone give me an estimate of what the repair cost might be? Does it do damage to continue to drive it short distances?

Also, has anyone had any experience with a "compressor bypass pulley"?
A1Auto.com sells it as an alternative to costly ac repairs. it is suppose to mount where the compressor goes. Was wondering how hard it would be to install?
I can do without ac but would like to use the van to haul stuff sometimes.
thanks

If the bearings in the hub are ok, and the clutch is the problem, remove the clutch from the compressor and you should be good to go. If the hub bearings are bad, remove the compressor and install the bypass pulley and bracket.

Thanks. Do you know if it requires any special tools and/or experience to remove either one? I was trying to locate an online manual but have yet to
do so.

To remove the compressor: Remove the upper fan shroud to access the serpentine belt tensioner and remove the belt. The refrigerant needs to be drained. Remove the bolt on the rear of the compressor that holds the manifold connection to the compressor. Remove 4 bolts holding the compressor to the mounting bracket. Disconnect the clutch field electrical connector. Move the compressor forward and disconnect the high pressure cut out switch connector on the rear of the compressor. Lift the compressor out. Install the new bracket and pulley. Reinstall the serpentine belt and fan shroud.

Removal of the clutch requires a special puller. You can "borrow" the puller at Advance Auto Parts or Autozone. You will need to remove the upper fan shroud for access to the front of the compressor. Do not remove the serpentine belt. Disconnect the coil wire from the ignition coil. Turn the ignition to the RUN position. Turn the HVAC mode switch to the AC position. Remove the center bolt holding the clutch to the compressor shaft. Turn the ignition to the OFF position. Install the special tool and press the clutch off. Reconnect the ignition coil wire.

sorry to dredge an old thread up, but if you just remove the idler pulley you can run a smaller belt (think it was around 83") and completely miss the AC pump without dealing with purging the system and purchasing a pulley. Belt goes directly from PS pump to Alternator.