Noise coming from A/C clutch! Not Tensioner Pulley

[digitaltexan2u]

Hey everyone!
I've got a 2001 Limited and have recently had a noise coming from the front end. After going through ALL 88 pages here, i've found out that a lot of noises are found to be the Tensioner pulley. I looked under the hood, and the noise is definitely coming from the A/C clutch.

My question is...can I just replace the clutch assembly, or do I need an new compressor? The noise is like a "warbling", or "metal chirping" noise. As far as I know, it goes away once underway...returning when you stop.

Any help would be GREATLY appreciated!!

[LeSabre97mint]

Originally Posted by digitaltexan2u

Hey everyone!
I've got a 2001 Limited and have recently had a noise coming from the front end. After going through ALL 88 pages here, i've found out that a lot of noises are found to be the Tensioner pulley. I looked under the hood, and the noise is definitely coming from the A/C clutch.

My question is...can I just replace the clutch assembly, or do I need an new compressor? The noise is like a "warbling", or "metal chirping" noise. As far as I know, it goes away once underway...returning when you stop.

Any help would be GREATLY appreciated!!

Hello

I do believe that clutches for AC compressors are available for replacement.

I would suggest taking your belt off and run the engine for a bit. (not too long you will not have a water pump moving the coolant and the engine will get hot) and see if the noise is still there.

I've never replaced an AC clutch...I'm sure a manual has the process listed out.

Reagards

Dan

[digitaltexan2u]

I know it's coming from the clutch, because (((don't laugh))) I stuck a small diameter 6ft hose in my ear, and put the other end near the tensioner pulley....no noise. I then stuck it on the clutch assembly and it was squaking!

I'll call the local Ford dealer and see if the clutch assembly can be purchased seperately.

Thanks for the reply!

[corning_d3]

A new clutch can be had, but if you run it that way too long, you'll weaken or break the nose off of the compressor. Changing the clutch isn't too terrible, but removing the compressor may be..

[digitaltexan2u]

Thanks for the info!
Can I remove the clutch assembly without removing the compressor? I'd like to remove as little as possible.
Thanks!

[digitaltexan2u]

Ok...just got off the phone with the Ford Dealer.

Apparently this comes in three pieces.
1) Clutch. ($22.48)
2) Pulley. ($118.00)
3) Field. ($48.40)

What the heck is the "field"? Is that the piece that's on the outside of the pulley?

Does anyone have a pic of this?

THANKS!!

[12Ounce]

Is the clutch engaging or not? You can determine by looking for the air gap (about .5mm) just outside the belt pulley ... the gap closes when the clutch engages.

If you find it engaging just for a bit, then quickly releasing ... kinda oscillating ... you may just be low in refrigerant.

[phil-l]

The "field" is the electrical coil that creates the magnetic field that engages the A/C clutch. If the A/C clutch is engaging, the field is fine.

I've only replaced 1 A/C clutch (a GM product), and it wasn't a terribly difficult DIY job.

I didn't have to remove the compressor or vent the A/C system (so no Freon issues) in my situation; I had enough clearance to work. I haven't looked closely at my Windstar A/C, so I can't comment on how much rooom is available.

I did need to buy an A/C clutch removal tool (couldn't find a rental, but it was under $20, IIRC). It was simple jig that threaded into the female threads on the front of the clutch, and had a threaded rod in the middle that could be tightened, pushing the clutch off of the shaft. Mine looked very similar to what you'll see here:

http://mvpro.com/mall/Clutch_R&I_kits.asp

I believe the Windstar will use a similar tool (those with Windstar-specific experience, please chime in).

Your "listen through the hose" trick is a valuable diagnostic method. I have a mechanic's stethoscope, designed for auto work; it was cheap through Harbor Freight, and very useful.

[angleton]

Having just replaced a compressor, I can tell you there is not enough room to put the clutch puller tool on the front unless Ford got really creative in the desgn of the special tool. The top has loads of clearance, the bottom has about the width of the belt in clearance. The bolts on the compressor are easy to remove if you have to shift it to get enough clearance, but to remove it (on my 2002) I had to remove the alternator and alternator bracket to get it out.

Good luck

Owen

[garync1]

Originally Posted by digitaltexan2u

I know it's coming from the clutch, because (((don't laugh))) I stuck a small diameter 6ft hose in my ear, and put the other end near the tensioner pulley....no noise. I then stuck it on the clutch assembly and it was squaking!

I'll call the local Ford dealer and see if the clutch assembly can be purchased seperately.

Thanks for the reply!

Hey a long screw driver or pry bar works well also. Good trick if it works for you...I would also get it as close as you can to water pump too see if any noise is comming from there. the last few cars i have worked on had bad water pumps that did not leak but raises a heck of alot of noise. I thought it was a pully or bad ac.. If you are sure than the AC is most likley the problem..If it is the AC clutch sometimes the compressure may not be to far behind..

[digitaltexan2u]

Hey guys,
I'm going to do this repair this coming weekend. I looked through a Chiltons, or Haynes manual yesterday, but it didn't have any good pictures, or write up covering the clutch removal. Does anyone have and write ups, or photos showing this removal process? Thank you!!

[BIKNICKEL]

Originally Posted by digitaltexan2u

I know it's coming from the clutch, because (((don't laugh))) I stuck a small diameter 6ft hose in my ear, and put the other end near the tensioner pulley....no noise. I then stuck it on the clutch assembly and it was squaking!

I'll call the local Ford dealer and see if the clutch assembly can be purchased seperately.

Thanks for the reply!

Thank you for posting this one I have had similar problems on my 89 supra and yes I too located it with a Shop Vac extention. Great minds think alike. thank you, thank you, thank you.

[wiswind]

I seem to remember seeing the clutch assembly replacement process on the Autozone site for the '95-98 windstar.
I have not needed to replace that on my '96, so I do not have any experience with it......and I know that things were moved around a bit by your year.
The Alldatadiy site also has some great repair instructions, but is by subscription.....and I only have access to the repair information that is relevant to my year.
There is a TSB for my year regarding the pulley for the A/C.
There was a groaning sound that could be generatated in hot weather....and with the A/C running. The groaning sound was found to be caused by a resonance that only happened in hot weather, and was corrected by replacing the pulley on the A/C compressor with a slightly larger diameter pulley.
Might be worth the $25 for the repair instructions and the access to the TSB's.
They do update your information as new TSB's come out in future years, that apply to your year of vehicle.

I also had a noise issue that ended up being the bearings in the idler pulley....which is located right in the middle of the water pump, Alternator, power steering pump, and A/C compressor.
It was tough to diagnose, as it would only make noise at an RPM at, or above idle.....spinning anything by hand did not help. The Idler pulley is cheap....takes a bit to get the bolt loose.
I would give yours a spin......and replace if it feels slightly "grainey" when you turn it.
I mention this, as you will have the belt off.....so is easy to do at that time.

My water pump made only a very slight sound when I turned it......I would guess the sound was the seals.....but NO binding or grinding.
The alternator should NOT make a grinding sound (I had one that did). Give it a spin, and look for any wobble of the pulley.
Power steering pump feels strange to turn......even on a new pump.

[road_rascal]

Seeing as were on the subject of A/C compressor clutches, every once in awhile when I turn on the A/C in my '01 the clutch sometimes grinds when it engages. Not always, maybe a dozen times in the last 2 years. The loud noise lasts maybe for half a second then runs fine. I'm wondering if the "field" or coil is starting to go bad.

[corning_d3]

Maybe the clutch needs adjusting. On most I've seen, the air gap is adjustable.