Compressor Clutch

Replacement Procedure
P-1411
Installation Instructions
819-0361
 World Clutch with Unidamp® Step 2. Removing Hub/Armature Assembly (3)
Armature Assembly for Ford FX-15 A. Remove shaft bolt (6).
and FS-10 Compressors and all
Denso Models with 30mm bearing fit. B. Remove washer (5).

Keep fingers, hands and other C. Remove hub/armature (3) by hand. World
body parts and loose clothing away from Clutch has an 8mm threaded hole to use as a
rotating components. jack screw for removal.

Failure to follow these D. Remove shims (4) from the hub/armature

instructions may result in product damage, assembly. The number of shims can vary.
equipment damage, and serious or fatal
injury to personnel.
Rotor/Pulley to 1
Hub/Armature airgap 2
Compressor Clutch Removal 0.018" to 0.030" new part
0.013" to 0.025" used part
(measured 120˚ apart)
Note: Do not pound on the clutch, compressor
or Unidamp as damage will result to Unidamp ®
8
components. Hub/Armature
Rotor/Pulley Assembly
Assembly

Step 1. Diagnose Clutch Failure

Most compressor clutch failures are a direct
Field/Coil
result of items external to the clutch. These can Assembly
7
include compressor failure, electrical problems, 12
or oil contamination. Before installing a new
clutch, determine what caused the old clutch 10
to fail and fix the problem. 3

If the clutch is replaced without fixing the cause

of the clutch failure, the new clutch may fail in
the same manner as the old clutch.

11 9 5
Please refer to Warner Electric's “Air
Conditioning Clutch Troubleshooting Guide,”
form number P-1011, and the appropriate 13
6
manufacturer's A/C service manuals.
4
(Figure 1) Clutch Components

2 Warner Electric • 800-825-9050 819-0361

 Step 3. Removing Rotor/Pulley Assembly (8) Installing Clutch on Compressor
A. Remove rotor/pulley snap ring (9).
Replace the complete clutch to ensure full
B. Slide rotor/pulley assembly (8) off the com- performance is achieved and warranty
pressor nose (10). If rotor/pulley assembly is requirements are met.
hot it will not slide, do not force. Allow the
Step 1. Compressor Preparation
clutch to cool and then proceed.
A. Clean compressor nose of all dirt, grease
Step 4a. Removing Field Coil Assembly (12)
and debris. Check for evidence of oil leakage
for all compressors except Ford FX-15 & FS-10
from compressor front seal and through
A. Separate electrical connection and, if appli- bolts. Repair or replace compressor as
cable, remove clutch wire retaining clip from appropriate.
the compressor.
B. Check mounting surfaces (10) for nicks, burrs
B. Remove field coil snap ring (11) retaining the and scratches. (See Figure 1) Smooth with a
field coil. file or emery cloth if necessary. If severe wear
that affects field pilot or rotor bearing fit is
C. Remove the ground screw on the evident, the compressor must be replaced.
compressor, if used.
C. Check the electrical system to ensure that
D. Slide the field coil (12) off the compressor the voltage available to the clutch is 10.8
housing. volts minimum.

Step 4b. Removing Field Coil Assembly (12) for Step 2A. Installing the Field Coil (12) for all
Ford FX-15 & FS-10 only. (Refer to Figure 5 for fields except Ford FX-15 & FS-10
actual field configuration.)
Note: Failure to install snap rings per these
A. Separate electrical connection at the field. instructions can be verified and will void the
compressor clutch warranty.
B. Insert two pry tools between the rear of the
field shell (12) and the compressor housing. A. Align the anti-rotation pin in the back plate
These tools should be spaced 180 degrees of the field coil (12) with the hole in the
apart. Do not locate pry tool on terminal compressor housing. Guide the field coil
connector. assembly into the installed position. Make
sure that the leadwires are routed directly to
C. Gently pry the field coil (12) off the the retaining clip on top of the compressor,
compressor housing. if applicable.

B. With snap ring pliers, spread the field coil

snap ring (11) and insert it into the groove on
the compressor nose. (See Figure 2) To
assure assembly retention, the ring bevel
must face away from the compressor.
(See Figures 3 and 4)

Warner Electric • 800-825-9050 819-0361 3

 Rotor/Pulley Compressor Shoulder Do Not press
Assembly on Plastic Coil
body
Insert field
Field
installation tool
Assembly into inside diameter
Field Assembly of assembly
Compressor Pilot for
Compressor
Field Coil Assembly
Unidamp®
Field Coil Armature
Assembly Assembly Press
Compressor Shaft Direction
Snap Ring

(Figure 5) Ford FX-15 & FS-10 Field Installation

Rotor/Pulley
Assembly
Snap Ring Step 2B. Installing the Field Coil (12) for all
Ford FX-15 & FS-10 fields
(Figure 2) Location of Clutch Snap Rings A. Stand the compressor on end with the nose
pointing up. Position the field assembly (12)
Install with beveled face away from compressor such that the field shell starts to overlap the
Snap Rings
compressor nose field mounting surface.
Fully seated Ensure the electrical connector aligns with
snap ring
original connector position before continuing.

B. Insert the field installation tool into the inside

diameter of the shell. (See Figure 5)
Bevel
Compressor Compressor
Correct Incorrect C. Visually check to ensure the field is positioned
(Figure 3) (Figure 4) squarely. Press the field assembly onto the field
Snap Ring Correct and Incorrect mounting surface until it bottoms on the com-
Bevel Installation pressor shoulder.

C. Verify that the snap ring is fully seated in the

groove around its circumference to assure
assembly retention. (See Figure 4)

D. Attach ground lead, if used, to the compres-

sor housing and tighten screw.

E. Proceed to Step 3.

4 Warner Electric • 800-825-9050 819-0361

 Step 3. Installing the Rotor/Pulley Assembly (8) Note: As the shims may compress when
retainer bolt (6) is tightened, recheck airgap at
Note: Do not mar the rotor/pulley or hub/arma- three rivet locations (7).
ture drive surfaces. Prevent any oil or grease
from contaminating the friction surfaces. Step 5. Clutch Assembly Check

A. Install the rotor/pulley assembly (8) onto the A. Rotate the clutch and check for rubbing or
compressor (10). If the rotor/pulley does not interference.
slide easily, check the compressor nose for
nicks or burrs and remove them. If the B. Reinstall belts per manufacturer's service
rotor/pulley still does not slide on easily, rock manual. Do not over tighten.
the rotor/pulley back and forth by hand until it
slides completely onto the compressor (10). C. Recheck airgap at 3 or 4 points for clutch
rubbing. Airgap to be .018 to .030 inches.
B. Make sure there is no interference between
the field assembly (12) or leadwires and the D. Important: Burnish as follows. Run the clutch
rotor/pulley (8). at 2500 to 3000 RPM. Cycle the clutch ON
and OFF at a rate of 10 to 15 times per
C. With snap ring pliers, spread the rotor/pulley minute for a total of 50 cycles minimum. This
snap ring (9) and insert it into the groove on will assist in bringing the clutch up to operat-
the compressor nose per Figure 1. To assure ing torque capacity.
assembly retention, the ring bevel must face
away from the compressor. Cycle the clutch using the
(See Figures 3 and 4) controls inside the car or electrical system
damage could result.
D. Verify that the snap ring is fully seated in the
groove around the circumference to assure
assembly retention. (See Figure 4)

Step 4. Installing the Unidamp® Hub/Armature

Assembly (3)

Note: Do not insert screwdrivers between the

hub/armature and the rotor/pulley to remove
hub/armature as they will damage the clutch.

A. Slide the Unidamp Armature assembly (3) onto

the compressor shaft (13).

B. Set the rotor/pulley (1) to hub/armature (2)

airgap to .018 to .030 inches by adding or
removing shims (4). Measure using a feeler
gauge at 3 locations 120 degrees apart.
(See Figure 1) Should a used clutch be
installed, set the rotor/pulley (1) to hub/
armature (2) airgap to .013 to .025 inches.

C. Install washer (5) and retainer bolt (6).

Torque to 155 in. lb.

Warner Electric • 800-825-9050 819-0361 5

 Warranty

Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship
within a period of one (1) year from the date of original purchase for consumer, commercial or
industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information
may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449
Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you
will be notified and, with your consent, the item will be repaired or replaced and returned to you
at your expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any
defective product. Warner Electric LLC neither assumes nor authorizes any other person to give
any other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specifications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished
without charge on request to Warner Electric.

Warner Electric LLC

449 Gardner Street • South Beloit, IL 61080
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com

P-1411 819-0361 6/05 Printed in USA