A/C Fuse problem

My 93 Astro blew the A/C fuse. I trouble shot it and found it was not the blower motor by unplugging it. The compressor caused the fuse to blow when I turned on the A/C. I unplugged the compressor and the fuse didnt blow, even with the fan reconnected and the selector on A/C. I changed the compressor clutch magnet and everything was fine for about 6 weeks, problem is back. There is no accident damage or wire damage or butchery. I have owned this van since new. Any thoughts out there?

I would really think that your A/C compressor is drawing a lot of power. you should change your compressor. As it is old!!

Using a feeler gauge, how wide is the gap between the compressor clutch magnet and the clutch plate (check three places around the perimeter)?

What is the resistance of the clutch coil between the two leads?

What is the resistance of the clutch coil to a ground?

No matter if there is something inside the compressor that is causing the compressor to draw to much power and blow the fuse, it is still been hard on the compressor and will most likely not last much longer anyways. Your best bet is to just get rid of the problem and get another compressor. Whether it is from the parts store brand new, or a junkyard used.

I'm happy to report that I have found the problem! The wire harness going to the relays by the blower motor had chaffed against the accumulator pipe causing a short to the green wire that goes to the clutch. The Ford wiggle test did the trick!. Repair made and everything is cool again!